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Installation & Operation Manual

ESC 201 Electronic Module


JETKOOL Oil Cooling System

Copeland Screw Compressors

(Cx) ESC ter minal number Page 1 of 67 ESC201C-4-23-02


Preliminary Data Subject to change 4/22/02
Table of Contents
1.0 FUNCTIONS.......................................................................................................................................6
2.0 FEAT URES.........................................................................................................................................6
3.0 ESC 201 DESCRIPTION....................................................................................................................7
4.0 GENERAL OPERATIONS .................................................................................................................7
4.1 MANUAL MODE OPERATION .............................................................................................................. 8
4.2 A UTOMATIC MODE OPERATION ......................................................................................................... 8
5.0 ESC 201 INSTALLATION AND SET UP PROCEDURES.................................................................8
5.1 ESC 201 MOUNTING PROCEDURES .................................................................................................. 8
5.2 ELECTRICAL WIRING ......................................................................................................................... 9
Three Phase Wiring........................................................................................................................... 9
Shielded Cable Requirements........................................................................................................... 9
Communication Wiring....................................................................................................................... 9
Wiring Multiple Groups of Master and Slaves ................................................................................... 9
Terminating Jumpers ....................................................................................................................... 10
Communications Protocol................................................................................................................ 10
5.3 TRANSFORMER INSTALLATION AND WIRING ..................................................................................... 10
Power Requirements ....................................................................................................................... 10
Wiring............................................................................................................................................... 10
Fuse ................................................................................................................................................. 10
5.4 ESC 201 FUNCTION PROGRAMMING .............................................................................................. 11
5.5 ESC 201 SCREEN DISPLAY S .......................................................................................................... 11
Ready Screen................................................................................................................................... 11
Compressor Run Screen................................................................................................................. 12
Alarm Screen ................................................................................................................................... 12
6.0 FREQUENCY INV ERT ER OPERATION.........................................................................................14
6.1 INVERTER FAULT OPERATION .......................................................................................................... 14
7.0 DIRECT-ON-LINE OPERATION (DOL) ..........................................................................................15
8.0 PART WINDING START OPERATION...........................................................................................16
9.0 INV ERT ER RUN PROOF.................................................................................................................16
9.1 DIRECT ON LINE (DOL) / BY PASS RUN PROOF .............................................................................. 17
10.0 OPERATIONAL FUNCTIONS .......................................................................................................17
10.1 OIL SOLENOID OPERATION ........................................................................................................... 17
10.2 CAPACITY CONTROL / START UNLOADING..................................................................................... 17
10.3 RO TATION ..................................................................................................................................... 18
Pressure Switch............................................................................................................................... 18
Phase ............................................................................................................................................... 19
Phase Sequence Procedures .......................................................................................................... 19
10.4 ECONOMIZER SOLENOID ............................................................................................................... 19
10.5 OIL LEVEL CONTROL ..................................................................................................................... 19
Installation........................................................................................................................................ 19
Operation ......................................................................................................................................... 19
10.6 DIRTY OIL FILTER ......................................................................................................................... 20
10.7 LOW ECONOMIZER TEMPERATURE ................................................................................................ 20
11.0 PROGRAMMABLE OPERATIONS...............................................................................................21
Selecting Functions ......................................................................................................................... 21
Editing Functions ............................................................................................................................. 21
11.1 CO MPRESSOR TY PE ..................................................................................................................... 21
Mode Programming.......................................................................................................................... 22
11.2 OIL COOLING MODE ...................................................................................................................... 22
Jet Kool ............................................................................................................................................ 22
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Preliminary Data Subject to change 4/22/02
Liquid Injection................................................................................................................................. 23
None................................................................................................................................................. 23
11.3 JET KOOL TARGET TEMPERATURE................................................................................................. 23
Temperature Programming.............................................................................................................. 24
11.4 DISCHARGE TEMPERATURE RESET ............................................................................................... 24
Mode Programming.......................................................................................................................... 24
11.5 MOTOR OVERLOAD RESET ............................................................................................................ 24
Mode Programming.......................................................................................................................... 24
11.6 OIL FLOW RESET........................................................................................................................... 25
Automatic Mode ............................................................................................................................... 25
Mode Programming.......................................................................................................................... 25
11.7 OIL FLOW SENSOR ....................................................................................................................... 25
Digital Sensor................................................................................................................................... 25
Analog Sensor.................................................................................................................................. 26
Mode Programming.......................................................................................................................... 26
11.8 PHASE PROTECTION RESET .......................................................................................................... 26
Automatic Mode ............................................................................................................................... 26
Manual Mode.................................................................................................................................... 27
Mode Programming.......................................................................................................................... 27
11.9 PRESSURE TRANSDUCER TY PE .................................................................................................... 27
Mode Programming.......................................................................................................................... 27
11.10 DISCHARGE PRESSURE OFFSET ................................................................................................. 27
Mode programming.......................................................................................................................... 28
11.11 SUCTION PRESSURE OFFSET ..................................................................................................... 28
Mode programming.......................................................................................................................... 28
11.12 DISCHARGE \ SUCTION PRESSURE.............................................................................................. 28
11.13 MOTOR OVERLOAD MONITOR ..................................................................................................... 28
11.14 PHASE MONITOR ......................................................................................................................... 29
Mode Programming.......................................................................................................................... 29
11.15 CRITICAL DISCHARGE MONITOR .................................................................................................. 29
11.16 7- MINUTE TIME DELAY .............................................................................................................. 29
Mode Programming.......................................................................................................................... 30
11.17 COMPRESSOR START DELAY ...................................................................................................... 30
Mode Programming.......................................................................................................................... 30
11.18 TE MPERATURE PROBE TY PE....................................................................................................... 31
PTC .................................................................................................................................................. 31
PT1000............................................................................................................................................. 31
Mode Programming.......................................................................................................................... 31
11.19 DISCHARGE TEMPERATURE OFFSET ........................................................................................... 31
Mode programming.......................................................................................................................... 31
11.20 REFRIGERANT TY PE ................................................................................................................... 32
Mode Programming.......................................................................................................................... 32
11.21 SCREEN CONTRAST .................................................................................................................... 32
Mode Programming.......................................................................................................................... 32
11.22 DATE & TIME............................................................................................................................... 32
Mode Programming.......................................................................................................................... 32
11.23 POWER FREQUENCY ................................................................................................................... 33
Mode Programming.......................................................................................................................... 33
11.24 JE T KOOL SOURCE ..................................................................................................................... 33
Compressors.................................................................................................................................... 33
Rack Sensor .................................................................................................................................... 33
Mode Programming.......................................................................................................................... 33
11.25 LANGUAGE.................................................................................................................................. 34

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Preliminary Data Subject to change 4/22/02
Mode Programming.......................................................................................................................... 34
11.26 SLAVES ON LINE ......................................................................................................................... 34
11.27 I.D. NETWORK ............................................................................................................................ 34
Mode Programming.......................................................................................................................... 34
11.28 EXT / ECH ID............................................................................................................................. 35
Mode Programming.......................................................................................................................... 35
External Function Wiring ................................................................................................................. 36
Echelon Function Wiring.................................................................................................................. 37
11.29 N2 NETWORK MODE ................................................................................................................... 37
Master .............................................................................................................................................. 37
Slave................................................................................................................................................. 38
Terminating Jumpers ....................................................................................................................... 38
11.30 CONTROL BY :............................................................................................................................. 38
Local Control.................................................................................................................................... 38
Echelon Control ............................................................................................................................... 38
11.31 A LARM BOARDS.......................................................................................................................... 38
Mode Programming.......................................................................................................................... 39
11.32 ECHELON .................................................................................................................................... 39
Mode Programming.......................................................................................................................... 39
11.33 TE MPERATURE............................................................................................................................ 39
Mode Programming.......................................................................................................................... 39
11.34 PRESSURE.................................................................................................................................. 40
Mode Programming.......................................................................................................................... 40
11.35 FLOW RA TE................................................................................................................................. 40
Mode Programming.......................................................................................................................... 40
11.36 DATE FORMA T............................................................................................................................. 40
Mode Programming.......................................................................................................................... 40
12.0 MEMORY CHIP ..............................................................................................................................40
Exchanging the EEPROM................................................................................................................ 41
13.0 ALARM BOARDS ..........................................................................................................................41
Alarm Board I.D................................................................................................................................ 42
Alarm Board Wiring.......................................................................................................................... 42
14.0 REMOT E RESET............................................................................................................................42
15.0 MANUAL RESET ...........................................................................................................................43
16.0 LOGGING .......................................................................................................................................43
17.0 ESC 200 UPGRADE TO ESC 201.................................................................................................43
17.10 REMOVING THE ESC 200............................................................................................................ 43
17.20 INSTALLING THE ESC 201........................................................................................................... 43
17.30 ESC 200 A LARM FUNCTION TO ESC 201 A LARM BOARDS ......................................................... 44
APPENDIX A ..........................................................................................................................................45
COMPRESSOR MOTOR – PHASE - RUN PROOF CONFIGURATIONS...........................................45
APPENDIX B..........................................................................................................................................46
COMPRESSOR CONFIGURATIONS....................................................................................................46
APPENDIX C ..........................................................................................................................................47
EL ECT RICAL WIRING AND POWER SPECIFICATIONS...................................................................47
1. High Voltage................................................................................................................................. 47
Electrical Wiring and Power Specifications ..................................................................................... 48
2. Low Voltage.................................................................................................................................. 48
APPENDIX D..........................................................................................................................................49
Compressor Control Diagram.......................................................................................................... 49
APPENDIX E...........................................................................................................................................50
System Wiring Diagram................................................................................................................... 50
APPENDIX F...........................................................................................................................................51

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Preliminary Data Subject to change 4/22/02
ESC 201 Alarm Board...................................................................................................................... 51
APPENDIX G..........................................................................................................................................52
ESC 200 Conversion to ESC 201.................................................................................................... 52
APPENDIX H..........................................................................................................................................53
ESC 201 Low Voltage Transformer Wiring Diagram ...................................................................... 53
APPENDIX I............................................................................................................................................54
ESC 201 Trouble Shooting Guide................................................................................................... 54
JET KOOL INSTALLATION & OPERA TION MANUAL .........................................................................58
18.0 JET KOOL SYST EM......................................................................................................................58
18.1 DESCRIPTION ................................................................................................................................ 58
19.0 JET KOOL COMPONENTS...........................................................................................................59
19.1 LISTED BELOW ARE THE JET KOOL KIT COMPONENTS PROVIDED WITH JET KOOL. .......................... 59
19.2 LISTED BELOW ARE ADDITIONAL COMPONENTS REQUIRED , NOT SUPPLIED WITH JET KOOL............. 59
20.0 JET KOOL PIPING SPECIFICATIONS.........................................................................................59
20.1 MINIMUM CONDENSER HEIGHT ..................................................................................................... 59
20.2 PRIMARY JET COOL CONDENSER LINE (P1) .................................................................................. 59
20.3 SPLIT CONDENSER LINE (P2) ........................................................................................................ 59
20.4 OIL COOLER LIQUID LINE (P3)....................................................................................................... 60
Table 1.1 .......................................................................................................................................... 60
20.5 OIL COOLER V APOR RETURN LINE (P4) ........................................................................................ 60
20.6 HO T OIL FEED LINE (P5) ............................................................................................................... 60
Table 1.2 .......................................................................................................................................... 60
20.7 COOL OIL COMPRESSOR FEED LINE (P6)...................................................................................... 60
21.0 JET KOOL COMPONENT SPECIFICATIONS..............................................................................61
21.1 JET PIPE DESCRIPTION ................................................................................................................. 61
21.2 OIL COOLER PLA TE HEA T EXCHANGER DESCRIPTION .................................................................. 61
21.3 LIQUID FLOW CONTROL OPERATION ............................................................................................. 62
ESC 201 Configuration .................................................................................................................... 62
21.4 JKV 100 A NA- LOID V ALVE ............................................................................................................ 62
21.5 JKV 100 A NA- LOID COIL............................................................................................................... 63
21.6 SETTING MANUAL OIL COOLING .................................................................................................... 63
Specifications:.................................................................................................................................. 63
21.7 OIL COOLER FITTINGS................................................................................................................... 63
21.8 PRIMARY RECEIVER SHUT OFF V ALVE........................................................................................... 63
21.9 PRIMARY RECEIVER ...................................................................................................................... 63
21.10 LIQUID CHECK V ALVE ................................................................................................................. 64
21.11 LIQUID SIGHT GLASS .................................................................................................................. 64
21.12 ISOLATION BALL V ALVES............................................................................................................. 64
21.13 A CCESS FITTINGS ....................................................................................................................... 64
22.0 TROUBL ESHOOTING T HE JET KOOL SYST EM .......................................................................65
23.0 JET KOOL FL OW DIAGRAM........................................................................................................67

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Preliminary Data Subject to change 4/22/02
ESC 201
Installation & Operating Manual

1.0 Functions
1. Compressor Direct on Line Start Initialization
2. Compressor Part Winding Start Initialization
3. Compressor Sequencing Control
4. Compressor Rotation Control and Alar m
5. Compressor Short Cycle Prevention
6. Compressor Loader Start Delay
7. Compressor Direct on Line Run Proof
8. Compressor Inverter Run Proof
9. Discharge Temperature Control and Alarm
10. Motor Overload Control and Alar m
11. Oil Solenoid Control
12. Economizer Control
13. Oil Safety Control w ith Auto Reset and Alarm
14. Motor Phase Loss Protection
15. Oil Separator Level Control and Alar m
16. Dirty Oil Filter Alarm
17. Jet Kool Operation and Control
18. Critical Discharge Temperature Monitoring and Control
19. Liquid Injection Control
20. Low Discharge Temperature Monitoring and Control
21. Welded Contactor Protection
22. Alarm Logging w ith Retrieval
23. Echelon Communications Capability
24. RS-485 Communications Capability
25. Direct Compressor Operation via Com. Port

2.0 Features
1. Display Screen – 4 line, 20 Characters per Line
2. Programmable Functions and Alar ms
3. Four Button Control
4. Language Selection; English, Ger man, French, Italian, Portuguese, Spanish
5. Flashing Alarm Screens w ith Priority Levels
6. Input and Output Plug Ter minals
7. One Amp Fuse Protection on 20VAC Pow er
8. 5 Amp Fuse Protection on Control Pow er
9. Horizontal or Vertical Mounting
10. Control Reset Button
11. Remote Control Reset
12. Automatic Configuration of Control and Pow er Voltages
13. Snap Track Mounting
14. L.E.D. Operational and Communication Lights

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Preliminary Data Subject to change 4/22/02
3.0 ESC 201 Description
The ESC 201 control is an upgraded version of the ESC 200 w ith added features and
functions to further enhance and protect the Copeland screw compressor. The ESC 201
controls all compressor safety and operation functions through the use of a microprocessor
and various types of sensors.

The control w ill interface w ith either mechanical or electronic pressure controlled systems.
Safety functions requiring a compressor shutdow n can be reset w ith a built-in reset button
through the Echelon netw ork or via a remote reset activated by an electronic pressure
controller. Compressor alarms can be logged to an electronic pressure controller through
the Echelon or 485 netw orks. A general alarm output is provided to activate a panel light,
auxiliary alar m or relay. Internal per manent logging is provided on several functions to
record a permanent record on critical functions. This log can be used to assist in
troubleshooting or determining w arranty. Log functions w ill record date, time of occurrence
and cannot be erased except by the factory.

The ESC 201 w ill operate Copeland’s Screw compressors by several different starting
methods, such as: frequency drives, direct on line and part w inding start. Compressor
starting, stopping and capacity control operations can be controlled directly from the
electronic pressure controller or across the Echelon or 485 netw ork w ithout a controller
output point.

Most compressor control functions are compressor model specific requiring configuration via
the software by using the program buttons. Once the compressor has been selected, the
applicable functions can be established as either manual or automatic reset. Certain
functions are locked to specific compressor models and cannot be accessed through the
software. Critical compressor functions will alar m and shut dow n the compressor causing a
manual lockout or automatic reset sequence. If the alar m causes the maximum automatic
resets, the compressor will be locked out requiring a manual reset. Non-critical alar m
functions will generate an alar m notice allow ing the compressor to remain operational.

A four line tw enty character per line LCD screen displays compressor operational and
control information, as w ell as, compressor notices and alarms. These screen functions can
be displayed in six languages: English, Ger man, Italian, Portuguese, Spanish and French.
All control functions are programmed w ith four buttons located under the display screen.

Any ESC 201 can be selected as a master control through programming. The master
control is used to perform all communications from the slave controls and/or the Echelon
netw ork. Master units are the only controls allow ed to operate the Jet Kool function and
configure the slave controls for their initial setup. The Master ESC 201 can become Echelon
compatible by plugging in the “ E” hardw are into the master control board.

Snap track mounting provides easy mounting in the control panel. All low and control
voltage connections are performed w ith plug-in connectors for easy installation. A button
memory chip is utilized to retain control setting for each control.

4.0 General Operations


The compressor start sequence w ill be initiated w hen the ESC 201 receives a valid voltage
input signal at ( C1). The compressor output relays (C5, C6) w ill close and allow the
compressor to start after all static input functions have been checked to be w ithin acceptable
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Preliminary Data Subject to change 4/22/02
tolerances and all time delays have elapsed. Within the first 2 seconds of operation the ESC
201 w ill monitor for a valid phase sequence, rotation and run proof signal. If any of these
functions do not return a valid signal the compressor w ill shut dow n and lockout requiring a
manual reset. Once these valid signals are returned to the ESC, the oil solenoid w ill be
energized w ithin 2 seconds after start. After a 7 second delay from start the ESC w ill
energize the loaders as required by the system controller in their proper sequence.

After the compressor is operational for more than 7 seconds the ESC w ill continue to monitor
all safety functions until the next proper shutdow n or alarm function occurs. The monitored
safety functions consist of: Rotation, Run proof, Phase, Oil Flow , Oil Level, Motor Overload,
and Discharge Temperature. Any alar m in these areas w ill cause a compressor shut down
in the manual mode and/or automatic mode.

4.1 Manual Mode Operation


When operating in the manual operation mode any compressor shut dow n function w ill alarm
and leave the compressor in a shut dow n state until the manual reset button is depressed.
The manual reset can also be accomplished via the remote reset option. Rotation and run
proof function are a mandatory manual mode operation. Oil flow , discharge temperature,
motor overload, oil level, and phase monitoring can be set up in either manual or automatic
mode.

4.2 Automatic Mode Operation


Automatic mode allows the compressor to be restarted automatically by the ESC w ith the
strategy programmed for the individual function. Each functions automatic reset strategy will
be described in the section of the manual pertaining to that function. Functions, w hich are
allow ed operation w ith the automatic resets are : oil flow , discharge temperature, motor
overload, phase monitoring and oil level control.

5.0 ESC 201 Installation and Setup Procedures


Proper installation of the ESC 201 and setup of compressor parameters requires adhering to
the follow ing procedures. Programming of each compressor and the function parameter w ill
change depending upon the compressor model and type. A default list of parameter can be
found in section 5.4

5.1 ESC 201 Mounting procedures


The ESC 201 is provided w ith plastic snap track mounting. This snap track should be
attached to the electrical back panel w ith tech screws or another type of fastener, w hic h w ill
provide secure mounting for the control.

Ample space must be provided around the control for safety and accessibility purposes to
accommodate the removal of any w ire, terminal plug or fuse and not hamper access to the
manual reset button.

The ESC is provided w ith a UL required ground w ire attached to the ESC electronic circuit
board. All input functions reference a ground through terminals A7 and B7. This ground w ire
is the only ground source for the control and must be attached to the electrical back panel to
insure proper operation of the ESC 201.

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Preliminary Data Subject to change 4/22/02
5.2 Electrical Wiring

Three Phase Wiring


Three-phase pow er is required from the load side of the compressor contactor or the
compressor motor ter minals, to the thee phase connectors located on the right side of the ESC
201. DO NOT CONNECT FROM THE LINE SIDE OF T HE CONTACTOR. This w ill cause a
WIRING FAULT ALARM and prevent the ESC 201 from starting the compressor. This pow er
must be supplied from the load side of the contactor to assure proper electrical protection to
the system.

Shielded Cable Requirements


Located on the left side of board is a terminal plug w ith tw o terminals marked AC. These
terminals are the connection points for the 20VAC transformer pow er. Also located on this
plug are the tw o communication ports market (1+1-) and (2+2-). Shielded cable must be
used to connect both the pow er and the communication ports. It is also recommended all
input function w iring should utilize shielded cable from the input device to the ESC ter minal
point. Ter minal points w hich require shielded cable are, ter minals A1-A8, B1 to all other
points may be w ired using 16-gauge w ire.

All shielded cable must be grounded at one end of the cable to the same source as the ESC
ground. Shielded cable w ill provide protection against any possible electrical noise
transmission across the input or netw ork w iring to the ESC 201.

Comm unication Wiring


The ESC 201 is equipped w ith tw o communication ports (Comm.1 & Comm.2). These ports
must be w ired w ith shielded cable, one end of the shield connected to ground, to reduce to
possibility of noise transmission across the netw orks. The ESC 201 has an optional alar m
board. If used it must be w ired w ith shielded cable and grounded. The master and slave
boards are connected across the N2 netw ork using the Comm.2 ports. In any prescribed
group, a single master may be connected up to 11 slaves. More than one master can be
used on a system w here special control requirements exist.

Wiring Multiple Groups of Master and Slaves


When multiple master-slaves combinations are required the slaves must be daisy chain
wired to the master on the Comm. 2 ( N2) netw ork as a group and isolated from other groups.
The Comm. 2 netw ork is utilized to communicate control information from the slaves to the
master. Alarm boards are also daisy chain w ired on the Comm. 2 netw ork w ithin the group.
Alarm information is transmitted on the Comm. 2 netw ork from the ESC 201 to its
corresponding alarm board. (Refer to section on alarm boards for detailed information on the
operation of the alarm boards.)

Communications back to the rack controller w ill be accomplished via the Comm.1 netw ork.
All ESC 201 controls must also be daisy chain w ired on the Comm. 1 netw ork back to the
rack controller. When the Echelon netw ork is enabled, the communication link w ill be
accomplished by daisy chain w iring all the master controls, containing the Echelon Module,
back to the Echelon ter minal on the rack controller.

NOTE: See w iring diagrams located in the EXT/ECH ID Function section of this manual.

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Preliminary Data Subject to change 4/22/02
Term inating Jumpers
The ESC 201 is equipped w ith Comm. 1 and Comm. 2 ter minating jumpers. These jumpers
are located in the low er left corner on the board directly below the Comm. port ter minal block.
The Comm. 1 jumper must be placed across jumper pins (J5) on the last master control in the
netw ork. Example: When more than one master control is configured in a rack system, all the
Comm.1 ports on the master controls must be netw orked together w ith a signal shielded cable
back to the rack controller. The last master control in the netw ork must have the jumper in
place on (J5).
Comm. 2 (N2) netw ork terminating jumper (J6) is located below the Comm. 1 jumper ter minal
(J5). This jumper should be place across this terminal on the last board in the Comm.2
netw ork. This includes all ESC 201 and alar m boards connected on the Comm. 2 netw ork.

Comm unications Protocol


Comm.1 port has been provided to connect the master ESC controls to rack controller or
other device capable of accepting 485 communications. An open protocol w ill be made
available on request to allow other equipment suppliers to read the information from the ESC
201 controls.

5.3 Transformer Installation and wiring

Power Requirements
A 24-Volt, non-center tapped, A/C transformer is required to pow er the ESC 201. The
ESC 201 maximum operating current w ith Jet Kool and Echelon is 760 mA. As a safety
factor, a transformer should be selected w ith a 900 mA rating to operate one board. Multiple
ESC 201 boards can be operated from a single transformer designed to handle the total
pow er requirement. A pow er terminal block is provided on the left side of the ESC board to
accommodate the A/C pow er and the communication w iring. This terminal block has tw o
designated ter minals for the 24 volts marked “AC”. DO NOT CONNECT ANY POWER TO
TERM INALS MARKED [1+, 1- OR 2+, 2-]. These are serial communication ter minals and
damage w ill occur to the ESC if pow er is applied to these ter minals.

Wiring
Pow er w ir ing from the transformer to the ESC 201 must be w ired using shielded cable, w ith
one end of the shield grounded to the electrical panel back pan. Please refer to Appendix C
for the proper transformer w iring and detailed electrical specifications.

Fuse
24V pow er is fused on the board w ith a 3A fuse located directly above the AC pow er
connector.

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Preliminary Data Subject to change 4/22/02
5.4 ESC 201 Function Programming
The ESC 201 has the capability to operate all Copeland screw compressor functions. These
functions must be programmed as applied to each compressor model and type, as w ell as,
the function capability. Illustrated below are the operations to begin the programming mode.
Once the programming mode has been initiated, the programmer must scroll through each
function and set that function to the proper application for the compressor operation. The
setup screen can be accessed from the main screen or the compressor operational screen
by pressing any button.

Step #1 Step # 2 Step # 3

Setup Screen Category Selection


Main Screen

Unit: # ESC 201 ----------- Setup ESC ---------- ----------- Setup ESC ----------
Date Time Config Network Config Network
12/15/2000 06:30:00 Time Language
Time Language
JKV 100% JKT 180.0F Pick End Next
Main Select
1 2 3 4
1 2 3 4 1 2 3 4
1. CONFIG will be flashing
1. Press any button for setup screen 1. Press SELECT button (4) to pick catagory 2. Use NEXT button (4) to choose category
2. Press main (1) to return to main screen 3. The Choosen category will flash
4. Press the PICK button (1) to access category
5. Press END button (2) returns to last screen

5.5 ESC 201 Screen Displays


Listed below are screen displays, which w ill appear during the different modes of control
operation.

Ready Screen
Ready Screen
Unit: # (1) ESC 201 (2)
The ready screen w ill be displayed w hen the Date (3) Time (4)
compressor is in a ready for operation state. 12/15/2000 06:30:00
JKV (5) 100% JKT (6) 180.0F
(1) Unit # - displays the assigned unit number as
assigned in the comm. 2 netw ork. Unit #1 w ill alw ays be assigned as a mater control.
(2) ESC 201 (X) – displays the model number and version of software that has been loaded
into the control. Letters follow ing the model number designates the version of software.
(3) Date – displays the programmed date.
(4) Time – displays the programmed time.
(5) JKV – displays the percentage the Jet Kool valve is open.
(6) JKT – displays the average discharge temperature of all compressors operated by Jet
Kool on the comm. 2 netw ork.

NOTE: Item numbers (5) & (6) w ill only be displayed on the master control. These items w ill
show the current status of these functions, regardless of the master control compressor
status.

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Preliminary Data Subject to change 4/22/02
Com pressor Run Screen
Compressor run screen displays the operating status of the compressor during normal
operations. The last display line of the master
compressor run screen w ill display the current Unit 1 (1) C (2) L1(4) L2 (5) O (6) E (7)
Jet Kool status. Jet Kool status w ill not be TRT 30 (3)

displayed on a slave control. CDT 178.3F (8) DP 211.3 (9)

JKV (10) 28% JKT (11) 173.3


(1) Unit # - displays the assigned unit number as
assigned in the comm. 2 netw ork. Unit #1 w ill alw ays be assigned as a mater control.
(2) C – displayed w hen compressor is in operation.
(3) TRT – displays total run time of compressor.
(4) L1 – displayed w hen loader #1 is energized.
(5) L2 – displayed w hen loader #2 is energized.
(6) O – displayed w hen oil solenoid is energized.
(7) E – displayed w hen economizer solenoid is energized.
(8) CDT – displays compressor discharge temperature w hen PT1000 type temperature
probe has been installed in compressor. Will not display w hen using PTC probe.
(9) DP – indicates either differential pressure or discharge pressure depending on the
follow ing enabled functions.
1. DP - differential pressure when using analog oil flow switch and both discharge and
suction transducers are connected to the ESC 201.
2. DP - discharge pressure for all other operations w hen discharge transducer is
connected to ESC 201.
(10) JKV – displays the percentage the Jet Kool valve is open.
(11) JKT – displays the average discharge temperature of all compressors operated by Jet
Kool on the comm. 2 netw ork.

Alarm Screen
When a compressor alarm has been generated the flow ing type of display screen will
replace the compressor run screen. The actual compressor alar m generated w ill be a
flashing display on the screen. This alarm w ill remain displayed until the alar m has been
cancelled by an ESC 201reset function or by depressing the reset button.
Example #1
(1) Status of function in alar m state w hen
CDT 210 F (1)
applicable.
High Discharge Temperature (2)
(2) Alarm generated (alar m w ill be flashing).
(3) JKV – displays the percentage the Jet Kool JKV (3) 100% JKT (4) 180.0F
valve is open.
(4) JKT – displays the average discharge Example #2
temperature of all compressors operated by Jet
Kool on the
comm. 2 netw ork. Low Oil Flow (2)

JKV (3) 100% JKT (4) 180.0F

(Cx) ESC ter minal number Page 12 of 67 ESC201C-4-23-02


Preliminary Data Subject to change 4/22/02
The follow ing are ESC 201 functions that require programming:

Configuration Setup

FUNCTION INITIAL DEFA ULT


1. Compressor Type SHL1-7500
2. Oil Cooling Mode None
3. Jet Kool Target Temperature 180°F
4. Discharge Temperature Reset Automatic
5. Motor Overload Reset Automatic
6. Oil Flow Reset Automatic
7. Oil Flow Sensor Digital
8. Phase Protection Reset Automatic
9. Pressure Transducer Type Eclipse 500
10. Discharge Pressure Offset Master Only
11. Suction Pressure Offset Master Only
12. Discharge \ Suction Pressure Read Only
13. Motor Overload Monitor Enable
14. Phase Monitor Enable
15. Critical Discharge Monitor Enable
16. 7 Minute Time delay Enable
17. Compressor Start Delay 0 Seconds
18. Temperature probe Type PT1000
19. Discharge Temperature Offset 0
20. Refrigerant Type None
21. Screen Contrast 7 Bars
22. Date & Time Current
23. Pow er Frequency 60 Hz
24. Jet Kool Temperature Source Compressors
25. Language English
26. Slaves on Line Master Only
27. I.D. Netw ork 1
28. EXT / ECH ID 1
29. N2 Netw ork Mode Slave
30. Control By: Local
31. Alarms Boards Disabled
32. Echelon Disabled
33. Temperature Fahrenheit
34. Pressure PSI
35. Flow Rate Gallons/Min
36. Date For mat Month/Day

Each of these functions w ill be covered in detail throughout the manual. Configuration setup
mode allows the programmer to scroll through each of the 29 functions for configuration.
The setup screen contains 3 short cuts, allow ing the programmer to directly access the
netw ork, time & date and language screens. These three modes w ill require more
programming accessibility than the other 24 functions, eliminating a lengthy scroll process.

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Preliminary Data Subject to change 4/22/02
6.0 Frequency Inverter Operation
The compressor start sequence w ill be initiated w hen the ESC 201 receives a valid voltage
input signal at ( C1). The compressor output relay (C5) w ill close the inverter forward run
relay, initiating the inverter start sequence and allow ing the compressor to start. NOT E: If a
time delay can be programmed between the time the inverter receives a forw ard run
signal and voltage output to the com pressor, this delay m ust be set to zero seconds.
All static input functions must be verified as acceptable for the compressor to remain
operational.

Inverter operation is determ ined autom atically w hen the ESC senses a closure of the
inverter run proof at (A4). A 5 VDC signal is sent from the ESC to a dry set of inverter run
proof contacts provided by the inverter or a dry set of relay contacts operated by a voltage
output from the inverter. The closure of either of these contacts w ill return a 5 VDC signal to
the ESC indicating to the ESC it w ill be operating in the inverter mode. NOTE: DO NOT
APPLY A VOLTAGE SIGNAL ABOVE 5VDC TO TERM INAL (A4).

The compressor signal (C5) w ill remain energized to the inverter forward run relay while run
proof is being verified, permitting the inverter to reset automatically in the event of a fault. If
the run proof is not verified during the first 5 seconds of start, the alarm w ill be issued
displaying “Run Proof Failure” on the display. Functional operations such as: oil solenoid,
loader solenoids and economizer solenoid w ill remain inactive until the run proof is verif ied.
The compressor w ill remain operational for an additional 5 seconds w aiting for the run proof
to be verified. Once the 10 seconds has elapsed w ithout a run proof or being sw itched into
the by-pass mode, the compressor w ill be shut dow n requiring a manual restart.

If the inverter faults and the compressor is placed in the by-pass mode, the (direct on line)
run poof w ill be indicated by the closure of the auxiliary contacts on the (direct on line)
contactor. During this operation the ESC w ill perform the required phase operations
previously performed by the inverter.

NOTE: If both DOL and inverter run proofs are closed together, the compressor w ill be
shut dow n immediately, and a “Dual Run Proof” alarm w ill be displayed.

6.1 Inverter Fault Operation

Most inverters can be programmed to recognize faults, clear faults and perform automatic
restarts, if the fault can be cleared. To prevent the ESC from locking out the compressor
during inverter fault retries, the INV ERT ER FAULT SCHEM E must be w ired into the control
circuit. This scheme consists of a N/C relay (IFR) in series w ith the control voltage signal
input to ( C4). The (IFR) relay coil is energized by the inverter fault output each time the
inverter faults. When the inverter faults the (IFR) N/C contacts open, removing the voltage
signal from (C4), placing the ESC 201 in the ready mode. Additional set of N/O contacts can
be utilized on the IFR to place the inverter compressor into by-pass w hen IRF coil is
energized. Example of this scheme is illustrated below .

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Preliminary Data Subject to change 4/22/02
Inverter Fault Scheme

208-230/60/1
CONTROL POWER

RACK
CONTROLLER LOW PRESSURE HIGH PRESSURE
RELAY INVERTER RESET
CONTROL CONTROL 13 14
C 2
COMPRESSOR
ON - OFF SWITCH COMPRESSOR CONTROL INVERTER
RESET RELAY

9 5 13 14
C
2 10 INVERTER INVERTER BYPASS
C FAULT RELAY CONTROL RELAY

INVERTER BYPASS INVERTER BYPASS COMPRESSOR


TIME DELAY INVERTER
CONTACTOR
9 5 1 3 AUXILIARY CONTACTOR
9 1
15 C 2
INVERTER BYPASS INVERTER BYPASS INVERTER
CONTROL RELAY TIME DELAY FAULT RELAY
2 10
C 13 14
C
INVERTER
TIME DELAY VARABLE SPEED
12 IFR 4 9 5 1 3 CONTROL RELAY
19
INVERTER VARIABLE SPEED INVERTER
FAULT RELAY CONTROL RELAY TIME DELAY
ESC 201
C1

Inverter Fault INVERTER


Scheme
INVERTER
FAULT 13 14
OUTPUT C
INVERTER ESC-IFS.wmf
FAULT RELAY

7.0 Direct-on-Line Operation (DOL)


Compressors operated direct on line rely upon tw o voltage signals to deter mine this method
of operation. A 115V run proof signal supplied to ( C4) and the three-phase voltage signal
supplied to right side of the ESC 201, labeled L1 {A}, L2 {B} and L3 { C}.

Tw o seconds after start, rotation w ill be verified allow ing the oil solenoid to activate. Within
this time all operational functions w ill commence in sequence. Five seconds after all
functions have been verif ied as operational, the loaders w ill energize and the compressor
will remain operational.
If the run proof is not verified w ithin 5 seconds from start, the compressor w ill be shut dow n
and a “Run Proof Failure” alarm w ill be displayed. If the run proof is lost during operation
the oil solenoid and loaders w ill be turned off immediately. After a fiv e second delay the
compressor w ill be shut dow n, unless the run proof has been reestablished, at w hich time
the oil solenoid and loaders w ill be reactivated.

See Appendix A “Direct on Line”


NOTE: If both DOL and inverter run proofs are closed together, the compressor w ill be shut
dow n immediately, and a “Dual Run Proof” alarm w ill be displayed.

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Preliminary Data Subject to change 4/22/02
8.0 Part Winding Start Operation
The ESC 201 has been designed to perform the part w inding start operation w ith a primary
start w inding output (C5) and a secondary w inding output ( C6). The secondary w inding
output w ill energize ½ second after the primary w inding output. Voltage monitoring for
phase loss and phase symmetry w ill be accomplished from the primary start contactor.

Run proof verification must be accomplished w ith N/O auxiliary contacts on the primary and
secondary contactors. These auxiliary contacts must be w ired in series to terminal (C4).
NOTE: Refer to section on “(DOL) Run Proof” for proper wiring procedures.

Tw o seconds after start, rotation w ill be verified allow ing the oil solenoid to activate. Within
this time all operational functions w ill commence in sequence. Five seconds after all
functions have been verif ied as operational, the loaders w ill energize and the compressor
will remain operational.

If the run proof is not verified w ithin 5 seconds from start, the compressor w ill be shut dow n
and a “Run Proof Failure” alarm w ill be displayed. If the run proof is lost during operation
the oil solenoid and loaders w ill be turned off immediately. After a fiv e second delay the
compressor w ill be shut dow n, unless the run proof has been reestablished, at w hich time
the oil solenoid and loaders w ill be reactivated.

See Appendix A “Part Winding Start”

9.0 Inverter Run Proof


When a frequency inverter operates a compressor, the inverter (due to time delays) must
supply the run proof signal and other software configurations. The inverter is configured w ith
a dry set of N/O contacts, w hich are used to return a 5 VDC signal back to the ESC 201
telling the ESC the compressor is operational. If these contacts are utilized by another
device requiring a high voltage signal such as 110V or 230V, an isolation relay can be used
with the same coil voltage. This relay can be used as the run proof to supply a signal back
to the ESC 201.

Run proof set up is sensed automatically w hen the inverter run proof contacts closes the
circuit to (A4) for inverter operation or the compressor contactor auxiliary closes the circuit to
(C4) for direct on line operation. If the ESC 201 senses a closure at both (A4) and (C4)
simultaneously the ESC is designed to fail and alar m “Dual Run Pr oofs”, locking out the
compressor. All operational functions, such as oil solenoid and loaders; w ill remain inactive
until a run proof is verified. If the run proof is not verified w ithin 5 second from start, the ESC
will alar m “Run Proof Failure” at the end of an additional 5 seconds. The run proof has
not been confirmed the compressor w ill be shut dow n requiring a manual reset.

Depending upon the OEM and their methods of controlling inverter compressors, a by-pass
scheme may be implemented before the compressor is locked out on the run proof alarm. A
method of w iring an automatic by-pass can be found in section 6.1 “ Inverter Fault Scheme”.
By pass run proof operation is discussed in section 9.1” Direct On Line” run proof.

See Appendix A “Inverter”

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Preliminary Data Subject to change 4/22/02
9.1 Direct On Line (DOL) / By Pass Run Proof
Direct On Line run proof w ill automatically be configured w hen the compressor is started. If
a DOL run proof is required, a voltage signal w ill appear at ter minal C4, indicating a DOL run
proof is required. This method of run proof sensing is utilized w hen compressors are
operated direct on line or a by pass is required w ith an inverter compressor. A high voltage
signal (110V or 230V) must be supplied from L1 through a compressor contactor auxiliary
closure to (C4). A valid run proof signal must be verified before the ESC w ill activate the oil
solenoid. After 5 seconds the ESC 201 w ill display the Alar m “Run Proof Failure” and at
the end of 10 seconds the compressor w ill be shut dow n requiring a manual reset, if the run
proof has not been confirmed. If the ESC 201 senses a closure at both (A4) and (C4)
simultaneously, the ESC is designed to fail and alar m “Dual Run Proofs”, locking out the
compressor.

See Appendix A “Part Winding Start”

10.0 Operational Functions


Operational functions consist of devices, which operate valves, and devices that are required
to start and run the screw compressor. These devices incorporate the oil solenoid, loader
solenoids, economizer solenoid, rotation sw itch, and oil level control. These devices do not
require any configuration or programming. The operations for these devices are factory
preset and cannot be altered.

10.1 Oil Solenoid Operation


The oil solenoid output relay (C9) w ill energize 2 seconds after the compressor start
sequence has been initiated, allow ing oil to flow to the compressor. During the 2 second-
time interval, if either the rotation or run proof has not returned a signal to the ESC 201 the
compressor w ill shut dow n requiring a manual reset. Any time the compressor stops, either
normally or due to a fault the oil solenoid w ill close, preventing oil from flooding the
compressor. The 2 second oil solenoid delay w ill also provide reduced loading during part-
winding-start operation.

It is recommended that a solenoid coil light be mounted in the coil and w ired in parallel
indicating pow er has been applied to the solenoid coil. This provides the service technician
visual proof the solenoid has been energized.

10.2 Capacity Control / Start Unloading


After the compressor start sequence has been initiated for a period of 5 seconds, the
capacity control regulators [CR] w ill activate in accordance w ith the program prescribed by
the ESC 201. These capacity control regulators are referred to as loaders, since they must
be electrically energized to load the compressor. The electronic rack controller w ill perform
the operation of controlling the loaders for the purpose of capacity control. The function of
the ESC 201 is insure the loaders remain de-energized during start conditions and their
sequence of operation conforms to Copeland’s prescribed operation. By insuring these
capacity regulators remain de-energizer during start they w ill also perform the function of
start unloading to assist in the part-w inding-start operation.
The prescribed operation sequence for each model compressor is listed below .

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Preliminary Data Subject to change 4/22/02
“SHM2 & SHL2” Unloading sequence Loading sequence
“SHM1-5000 /6000”
“SHL1-4000 / 5000”
Step #1 CR1 de-energize (C7) CR2 energize
Step #2 CR2 de-energize (C8) CR1 energize

“All Others” Unloading sequence Loading sequence


Step #1 CR2 de-energize (C8) CR1 energize
Step #2 CR1 de-energize (C7) CR2 energize

Note: For the proper loader identification by model, refer to Appendix “B” in the rear of this
manual.

When the loaders are w ired in the correct sequence from the ESC 201 to the compressor
capacity control regulator solenoid, the ESC w ill operate these solenoids in the proper order
regardless of the input signal sequence from the rack controller. CR1 must be w ired from
(C7) and CR2 must be w ired from (C8). The rack controller w ill supply a signal to energize
either loader #1( C2) or loader #2 (C3) based on the scheme setup by the rack controller
manufacture. Different rack controllers have several types of logic to control capacity, which
may conflict w ith the required sequence Copeland needs to insure a safe and efficient
compressor operation. For this reason the ESC 201 w ill perform the proper loading and
unloading sequence regardless of the demands set by the rack controller.

Operating voltage for the capacity control regulators is determined by the voltage input to
terminals (C2 & C3). The voltage applied to these ter minals w ill be sent out through
terminals (C7 & C8) respectively. The ESC capacity control voltage limitations are from 90 –
250 VAC and 12 - 24 VDC

10.3 Rotation
Rotation deter mination is accomplished by 2 methods, a pressure switch and phase
sequence. Both of these methods w hen used in conjunction w ill insure the proper rotation of
the compressor. This function is a non-programmable function requiring only the proper
installation and w iring of the devices used to determine rotation. Rotation can only be reset
manually.

Pressure Sw itch
Compressor rotation verification is accomplished in tw o methods, both of w hich must be
verified to continue operating the compressor after the 2 second start sequence. The
primary method to detect reverse rotation is a sw itch mounted on the front of the
compressor. This sw itch senses the pressure in the rotor chamber to deter mine the proper
direction of rotation. The sw itch w ill close when the pressure rises above 20 PSI and opens
at 10 PSI. The sw itch becomes an active part of the rotation control scheme after an
elapsed starting time of 2 seconds. After this 2 second time delay the ESC w ill check the
status of the sw itch to determine rotation. If the sw itch is closed, a 5 VDC signal is sent from
terminal (A3) back to (A7), indicating the compressor is operating in the correct direction and
allow ing the compressor to remain operational. After the 2-second time delay and the ESC
determines the sw itch is open, the compressor w ill be shut dow n and the alarm “Rotation
Failure” will be displayed on the ESC screen.

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Preliminary Data Subject to change 4/22/02
Clearing this alar m w ill require a manual reset. The pressure sw itch is a high pressure rated
sw itch designed specifically for this application. This sw itch requires the use of a vibration
damper mounted betw een the compressor and the sw itch. If this switch or compressor is
changed for any reason the old vibration damper can be utilized. Inspect the damper to
determine that the internal filter has not been damaged. Do Not use the old vibration
damper if is determined to be defective. To determine proper assembly of the rotation
sw itch for each compressor type, refer to appendix B, figures 1 through 4.

Phase
The second method to deter mine rotation is by checking phase sequence. This check is
determined w ith the ESC softw are utilizing the three phase input signal supplied from the
phase terminals. When w ired properly the software determines the proper rotation w ithin ½
second from the initial start sequence. If the rotation is incorrect the compressor w ill be shut
dow n and the ESC w ill display the alar m “Phase Rotation”. Follow the below listed phase
sequence procedures to correct the fault.

Phase Sequence Procedures


During initial startup procedure, check for proper phasing of the ESC 201 to insure Phases
[A, B, C] from either the compressor terminals or the load side of the contactor to the
corresponding [A, B, C] phases on the ESC 201 are correctly w ired. If the compressor is
determined to be operating in the correct direction, w ith pressure gauges or visually on the
open type compressors, and the “phase rotation” alar m shuts dow n the compressor, the
phase w iring may be incorrect. This w iring correction can be accomplished by changing the
position of any tw o w ir es on the ESC phase connector. WARNING! Make sure the
compressor is operating in the correct direction before any wiring is altered.

10.4 Economizer Solenoid


Ter minal (C11) is designated as the economizer output. This relay point w ill energize a
solenoid to operate the economizer. The economizer output w ill energize 2 second after the
initial compressor start.

The ESC 201 has an enhanced feature to monitor discharge temperatures on both the high
and low extremes, providing the best protection possible to the compressor. The low
discharge function may require disabling of the economizer to perform certain diagnostic
checks on the system. To accomplish this check and others, it is important the economizer
(C11) output be utilized w ith the compressor.

10.5 Oil le vel Control

Installation
The oil separator is fitted w ith a ¾” –16 UNJF-3A threaded female adapter to accept a male
optical w ell assembly. The w ell per mits the removal of the electronics w ithout the loss of oil
or refrigerant. The sensor w ell should be tightened by hand not to exceed a torque value of
15 ft-lbs.

Operation
The sw itch sends out a light beam that is refracted by the presents of oil. When the oil level
falls below the optical sensor, light is no longer refracted opening the electronic contacts in
the sw itch. In normal operation, a 5V DC signal is sent from the ESC 201 to the sw itch and
returned to the ESC indicating a proper level in the oil separator. When the optical sw itch
opens, the ESC 201 reads this signal as a low oil level and shuts dow n all compressors
affected by the low oil function. When the ESC 201 is configured as a master, the oil level
(Cx) ESC ter minal number Page 19 of 67 ESC201C-4-23-02
Preliminary Data Subject to change 4/22/02
control does not affect the compressor assigned to the master ESC. This compressor is
allow ed to remain in operation, to perform the oil return function return back to the separator,
preventing a total rack shut dow n. The main oil protection for the compressor connected to
the master ESC w ill be the oil flow switch. The compressor connected to the master ESC
can be safely operated, since the oil level below the optical sensor is sufficient to operate
one compressor. When the oil level returns to a level sensed by the optical sensor, a time
delay of three minutes must occur before any compressors are allow ed to restart. This
three-minute time delay prevents the short cycling of a compressor due to a possible rapid
drop in oil level.

Immediately after the optical level sensor sends a low oil level signal to the ESC 201 the
compressors affected by the oil level sensor w ill shut dow n and a “Low Oil Level” alarm w ill
be displayed on the ESC screen. The alar m w ill clear automatically once the oil level returns
and the 3- minute time delay elapses.

Wiring
The w hite, signal w ire, from the optical sensor must be w ired to terminal (A2) on all ESC 201
controls. Accomplish this by w iring the optical sensor signal w ire to the Master ESC 201
terminal (A2) and use a jumper w ire to the slave ESC 201 controls. The optical sensor
(5VDC) pow er must be supplied from ter minal (B8) on the Master ESC 201. Do Not
Jumper together these power supply terminals (B8) from the master to the slave boards.
This may cause damage to either the optical sensor or the ESC 201 controls.

Optical Sensor Specifications

Voltage 5VDC O-Ring Seal


O-Ring
Current 45mA Black (Ground)
Pressure Range 0-2500 PSI
Temperature Range -40°F to 212°F Red (5VDC)
O-Ring size #3-908
White ( Signal)
Housing Torque 15 ft-lbs Max. 1/2" NPT
3/4" - 16 Prism Housing Conduit
UNJF-3A Thread
Thread

10.6 Dirty Oil Filter


Each compressor is equipped w ith an oil filter. Located on the filter is a differential pressure
sw itch, w hich reads the pressure drop across the filter assembly. This sw itch is set to alarm
at 25 PSID. The dirty filter sw itch has 2 methods to indicate this alar m, a visual indicator
located on the top of the sw itch that changes from green to red and the electrical indicator,
which closes a set of contacts making a connection betw een terminals (A1) and (A7). When
the ESC 201 receives this signal, an alar m, “ Dirty Oil filter”, w ill be displayed on the ESC
screen. Once the filter has been changed the manual reset button on the ESC must be
pushed to clear the alar m.

The dirty oil filter function is not a compressor shut dow n function, it is only an alar m
function.

10.7 Low Economizer Temperature


If the compressor discharge temperature is determined to be less than or equal to 35°F
above the condensing temperature for a consecutive period of 30 minutes the ESC 201 w ill
alar m “Low Discharge temperature”. The economizer output ter minal (C11) w ill shutdow n the
economizer solenoid for a time period of five minutes. At the end of this 5-minute shutdow n
(Cx) ESC ter minal number Page 20 of 67 ESC201C-4-23-02
Preliminary Data Subject to change 4/22/02
the ESC 201 w ill check the discharge temperature to determine if the discharge temperature
has risen to a value of at least 45°F above condensing. If not ESC 201 w ill permanently
shutdow n the economizer, requiring a manual reset and display the alar m “LOW ECO
TEMP”.

If turning off the economizer solenoid does not raise the discharge temperature above the
condensing temperature by 45°F the economizer output (C11) w ill be energized, placing the
ECO back into operation, displaying the alar m, “Low Discharge Temperature”.

When the discharge temperature remains below the condensing temperature by at least
50°F the conditions exist to condense refrigerant at the outlet of the compressor. Low
discharge temperature can be attr ibuted in many cases to low super heat at the economizer
inlet. The low discharge temperature w ill cause premature bearing damage resulting in
compressor damage. The above function w ill protect the compressor from bearing damage
caused by low super heat conditions at the economizer. When the ”Low Discharge
Temperature” alar m appears rather than “LOW ECO TEMP”, the low super heat or liquid can
be coming from the compressor suction.

11.0 Programmable Operations


Many operational functions require a program change to insure the compressor or function
has been configured to perform a specific operation. Follow steps 1 – 3 illustrated in section
“5.0 ESC 201 Installation and Setup Procedures” to begin the programming steps for
configuration setup.

Selecting Functions
Pick the “ Config” category by pressing button #1. The first screen w ill be the “Compressor
Model” screen. If this function selection is not correct, then follow the “Edit Functions”
instruction below . If this selection is correct and you w ant to continue to the next function
press the “next button”. This w ill place you in the “Oil Cooling Mode” selection screen. Each
time you press the next button you w ill scroll forward to the next sequential function, or press
the “Prev” button for the previous function. To return to the main menu, press the menu
button and then the main button to return back to the Main Screen.

Editing Functions
If the correct function selection is not show n on the screen, then press the edit button and
the function selections w ill begin to flash. Next, press either the (+) or (-) sign buttons to
scroll forward or backw ards through the function selections until the correct selection
appears. When the correct selection is flashing on the screen, press the save button,
“Saving” that selection in memory. To continue the programming procedure for other
functions press the next button to move forw ard in the process. To return to the main menu,
press the menu button and then the main button to return back to the Main Screen.

11.1 Compressor Type


Compressor choices are listed as follows: SHM2-3000,SHM2-3500,SHM2-4000,SHL2-
2000.SHL2-2500,SHL2-3000,SHM1-5000,SHM1-6000,SHl1-4000,SHl1-5000,SHM1-
7000,SHM1-8000,SHM1-9000,SHL1-6000,SHL1-7000,and SHL1-7500 in the Semi-Her metic
models. The open drive model numbers are listed as SDM1-0084,SDM1-0100,SDM1-
0118,SDL1-0084,SDL1-0100,SDL1-0118,SDM1-0165,SDM1-0192,SDM1-0220,SDL1-
0165,SDM1-0192,and SDM1-0220. Mandatory functions for the compressor w ill be initialized
automatically w hen the compressor is selected. The correct compressor must be selected to
insure the proper protection has been setup for that compressor. Items that are

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Preliminary Data Subject to change 4/22/02
automatically setup by selecting the compressor type is; motor protection, 7- minute start
delay, and analog oil flow requirements. The Factory default for the compressor type is
“SHL1-7500”.

Mode Programm ing


Changing the compressor type is accomplished by follow ing steps 1-3 in section 5.0 to
obtain the category selection screen, then follow the instruction found in section “11.0
Programm able Operations”. After accessing the edit screen for “Compressor Type”, the
(+-) buttons w ill allow the programmer to scroll and select the required compressor. Once
the selection has been made, pressing the “Save” button w ill save the selection and return
the programmer back to the function screen allow ing the programmer to continue to the next
function or return to the main screen.

Function Setup
Function Setup

----------- Setup ESC ---------- ----------- Setup ESC ----------


Compressor Model Compressor Model
64 Semi 64 Semi
Prev Next Edit Menu Save + -

1 2 3 4 1 2 3 4

1. Press EDIT button (3) for edit mode


1. Press (+) or (-) to change compressor model
2. Press SAVE button (1) to save selection

11.2 Oil Cooling Mode


Oil cooling can be accomplished using several different methods. The nor mal methods
consist of Jet Kool, None (Air Cooled, Water Cooled) or Liquid Injection. Factory default for
this function is “None”.

Jet Kool
When Jet Kool is the method of oil cooling, the ESC control (designated as the master) must
be setup in the oil-cooling mode as “Jet Kool”. Changing the oil cooling mode is
accomplished by follow ing steps 1-3 in section 5.0 to obtain the category selection screen,
then follow the instruction found in section “11.0 Programmable Operations”.
After accessing the edit screen for “Oil Cooling Mode”, the (+-) buttons w ill allow the
programmer to scroll and select “Jet Kool” as the oil cooling method. Once the selection has
been made, pressing the “Save” button w ill save the selection and return the programmer
back to the function screen allow ing the programmer to continue to the next function or
return to the main screen.
Unit 1 C L1 L2 O E
Section 11.20 “Jet Kool Tem perature Source” explains TRT 30
the function setup procedures for the proper temperature
CDT 178.3F DP 211.3
probe. The ESC w ill read either the “ Compressors” or the
JKV 28% JKT 173.3
“Rack Sensor “ as the temperature source to operate the
Jet Kool control valve. The ESC 201 w ill display the Jet Kool temperature and the
percentage the Jet Kool valve is open. Show n in this paragraph is an illustration of the
master ESC operating screen in the Jet Kool Mode. The bottom display line shows the Jet
Kool Valve “JKV %” and the Jet Kool Temperature “JKT °F or °C”. The JKT is an average
of all compressor discharge temperatures w hen the ESC 201 is configured for
“com pressors” as the Jet Kool temperature source, or the discharge header temperature

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Preliminary Data Subject to change 4/22/02
when it is configured as “Rack Sensor”. When this function is configured for
“compressors” the average temperature is taken only from the operating compressors. The
compressor discharge temperature “CDT” is the temperature read in the discharge of each
screw compressor. The only time the “JKT” and the “CDT” w ill read the same value is w hen
a single compressor is in operation. The preferred method to operate the Jet Kool is using
the “compressor” source rather than the “Rack Sensor” source. The “Rack Sensor “ has
been provided to upgrade or replace the old style Jet Kool controls w ith a single temperature
sensor mounted on the discharge line, and the compressors are fitted w ith a PTC sensor
rather than the PT1000 sensor.

A terminal block located in the upper left corner of the ESC board labeled “Jet Kool” is
provided to connect the Jet Kool Valve using #18-2 shielded cable. Shielded cable is also
recommended for the temperature sensor w ires from the compressors and/or the rack
sensor temperature probes. The desired discharge temperature can be set in 11.3 “Jet Kool
Target Temperature”.

Liquid Injection
Each ESC 201 has the capability to control the discharge temperature by using a liquid
injection valve. This method of oil cooling is limited to a maximum of 10% of the compressor
capacity. The target temperature for this function is preset to control the discharge at 190°F
(88°C). After accessing the edit screen for “Oil Cooling Mode” the (+-) buttons w ill allow the
programmer to scroll and select “Liquid Injection” as the oil cooling method. The liquid
injection valve percentage open “LIV %” w ill be displayed on the bottom line of the ESC
operational screen.

Each ESC 201 w ill control the liquid injection valve for the
connected compressor. A terminal block located in the upper Unit 1 C L1 L2 O E
left corner of the ESC board labeled “Jet Kool” is provided to
TRT 30
connect the liquid injection valve using #18-2 shielded cable.
Shielded cable is also recommended for the temperature CDT 190.5F DP 211.3
sensor wires from the compressors and/or the rack sensor LIV 46%
temperature probes.

None
The third option for oil cooling is none. After accessing the edit screen for “Oil Cooling
Mode” the (+-) buttons w ill allow the programmer to scroll and select “ None” as the oil
cooling method. This method is normally selected w hen either air cooled, w ater-cooled and
no oil cooling is required. In the case of air and w ater-cooled oil coolers the preferred device
is an oil temperature mixing valve to control discharge temperature. Details on these
devices can be obtained by contacting the factory.

The last line of ESC display w ill be blank w hen the “None” option is selected for oil cooling.

11.3 Jet Kool Target temperature


Jet Kool Target Temperature can only be accessed if the Jet Kool oil cooling method has
been selected. The target range can be set from 165°F (74°C) to 195°F (90°C). Factory
default for this function is “180°F”.

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Temperature Programm ing
Changing the Jet Kool target temperature can be accomplished by follow ing steps 1-3 in
section 5.0 to obtain the category selection screen, then follow the instruction found in
section “11.0 Programm able Operations”. After accessing the edit screen for “Jet Kool
Target Temperature”, the (+-) buttons w ill allow the programmer to scroll and select this
temperature betw een 165°F (74°C) and 195°F (90°C). Once the selection has been made,
pressing the “Save” button w ill save the selection and return the programmer back to the
function screen allow ing the programmer to continue to the next function or return to the
main screen.

11.4 Discharge Temperature Reset


Discharge Temperature Reset allow s the programmer to configure this function for either
automatic or manual reset. The Manual Mode w ill shut dow n and lock out the compressor
when the discharge temperature reaches 212°F (100°C), requiring an operator to manually
reset the ESC 201, clearing the “ High Discharge Temperature Alar m” restarting the
compressor. The automatic mode w ill shut dow n the compressor when the discharge
temperature reaches 212°F (100°C). When the discharge temperature falls below
183°F/84°C the “High Discharge Temperature Alarm”, w ill be cleared, restarting the
compressor. When the compressor is reset automatically, the 7-minute short cycle delay
(Section 11.13) w ill take precedence over the function to prevent compressor short cycling.
Factory Default for this function is “Autom atic”.

Mode Programm ing


Changing the discharge temperature reset can be accomplished by follow ing steps 1-3 in
section 5.0 to obtain the category selection screen, then follow the instruction found in
section “11.0 Programm able Operations”. After accessing the edit screen for “Discharge
Temperature Reset”, the (+-) buttons w ill allow the programmer to scroll and select betw een
automatic and manual. Once the selection has been made, pressing the “Save” button w ill
save the selection and return the programmer back to the function screen allow ing the
programmer to continue to the next function or return to the main screen.

11.5 Motor Overload Reset


Motor Overload Reset allows the programmer to configure this function for either automatic
or manual reset. The Manual Mode w ill shut dow n and lock out the compressor w hen the
motor ther mistors exceed a temperature of 212°F (100°C), requiring an operator to manually
reset the ESC 201, clearing the “ Motor Overload Alar m”, restarting the compressor. The
automatic mode w ill shut dow n the compressor when the motor temperature reaches 212°F
(100°C), and as the motor temperature falls below the reset point, the “ Motor Overload
Alarm” w ill be cleared, restarting the compressor. When the compressor is reset
automatically the 7- minute short cycle delay (Section 11.13) w ill take precedence over the
function to prevent compressor short cycling. Factory default for this function is
“Automatic”.

Mode Programm ing


Changing the discharge temperature reset can be accomplished by follow ing steps 1-3 in
section 5.0 to obtain the category selection screen, then follow the instruction found in
section “11.0 Programm able Operations”. After accessing the edit screen for “Discharge
Temperature Reset ”, the (+-) buttons w ill allow the programmer to scroll and select betw een
automatic and manual. Once the selection has been made, pressing the “Save” button w ill

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Preliminary Data Subject to change 4/22/02
save the selection and return the programmer back to the function screen allow ing the
programmer to continue to the next function or return to the main screen.

11.6 Oil Flow Reset


Oil flow reset permits the programmer to configure this function for either automatic or
manual reset. The automatic or manual modes monitor the oil flow rate w ith either a digital
or analog sw itch. These sw itches are described in section 7, “Oil Flow Sensors”. The oil
flow reset mode is configured at the factory in the “Autom atic Mode”.

Autom atic Mode


When the reset mode is configured for automatic the compressor w ill be allow ed to
automatically restart 3 times, after an oil flow failure, before a manual lockout occurs. 5 – 6
seconds after the oil flow falls below the minimum requirements for safe operation the ESC
201 w ill shut dow n the compressor, displaying a “Low Oil Flow Alarm”. If 3 oil flow resets
occur within a 10-minute consecutive period the ESC 201 w ill lock out the compressor,
requiring a manual restart. This 10-minute timer is automatically reset back to “0” once an
elapsed time of 10-minutes passes without an oil flow failure. During initial starting
sequence the compressor w ill be allow ed to operate for 20-seconds to establish the required
oil flow . If the proper oil flow has not been established after the elapsed 20-seconds the
compressor w ill be shut dow n in either the automatic or manual mode.

When the reset mode is configured for manual start the compressor is allow ed to operate for
a period of 15-seconds to establish oil flow . The compressor w ill be shut dow n if the oil flow
falls below the minimum required flow rate. If after 15-seconds, a safe oil flow has not been
established the compressor w ill be shut dow n and a “Low Oil Flow Alarm” will be
displayed. Either depressing the reset button or activating the remote reset w ill accomplish
restarting the compressor. This mode is primarily used in trouble shooting procedures.

Mode Programm ing


Changing the oil flow reset can be accomplished by follow ing steps 1-3 in section 5.0 to
obtain the category selection screen, then follow the instruction found in section “11.0
Programm able Operations”. After accessing the edit screen for “Oil Flow Reset ” the (+-)
buttons w ill allow the programmer to scroll and select betw een automatic and manual. Once
the selection has been made, pressing the “Save” button w ill save the selection and return
the programmer back to the function screen allow ing the programmer to continue to the next
function or return to the main screen.

11.7 Oil Flow Sensor


2 types of oil flow sensors can be used to determine the proper oil
flow requirements to the compressor. These consist of a “Digital”
flow sensor, which opens an electrical circuit interrupting a signal
back to the ESC 201, or the analog sensor, w hich reads the oil
flow . Either sw itch has an established setting deter mining the
minimum oil flow requirement to safely protect the compressor.
Factory default for this function is “Digital”.

Digital Sensor
The digital sensor requires a differential pressure and a minimum Digital Oil Flow
oil flow to activate the switch. 2 different sw itches are required to
operate the entire series of compressors. The SHM2-3000/3500/4000 to SHL2-
2000/2500/3000 and SDM1-0084/0100/0118 to SDL1-0084/0100/0118 series of
compressors operate w ith a minimum (discharge to suction) differential of 45 PSIG (3.06

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Preliminary Data Subject to change 4/22/02
Bars) and a minimum flow rate of 1.6 GPM’S (6 l/M). This sw itch is painted blue for
identification purposes. All other compressors require a switch w ith higher flow requirements
of 90PSIG (6 Bars) minimum (discharge to suction) differential and a minimum flow rate of
2.6 GPM’S (10 L/M). This sw itch is a brass or silver colored. The digital sw itch has a brass
plunger, w hen lifted by the minimum oil pressure and flow combination, closes a contact,
sending an electrical signal back to the ESC 201. If the contact is opened after the
compressor reaches operational status, the ESC 201 w ill sense this as an unsafe state and
alar m a “Low Oil Flow ”, shutting dow n the compressor. Installation of the digital sw itch
must be after the oil filter to prevent foreign particles from obstructing the sw itch.

Analog Sensor
Analog sensor is a w heel type flow devic e, w hich uses a magnetic pickup to count the
number of w heel rotations, w hich is converted to a 0-10VDC signal that can be read by the
ESC 201 and displayed in either gallons per minute or liters per minute. This sensor
provides a greater range of operation w hile providing the proper oil safety protection for the
compressor. If the oil flow falls below the minimum calculated oil flow rate for the present
conditions, the ESC 201 w ill shut dow n the compressor and display “Low Oil Flow”.
Installation of the analog sw itch must be after the oil filter to prevent foreign particles from
obstructing the sw itch.

The analog oil sensor requires additional information from the system to determine the
proper oil flow limitation. Information required consists of the discharge and suction
pressures of the system to calculate differential pressure. The pressure transducers supplied
by the pressure controller can be connected to the ESC 201 as the source for these
pressures. If these pressures are not supplied to each ESC 201 the control w ill shut dow n
the compressor on ” Low Oil Flow”.

Mode Programm ing


Changing the oil flow sensor can be accomplished by follow ing steps 1-3 in section 5.0 to
obtain the category selection screen, then follow the instruction found in section “11.0
Programm able Operations”. After accessing the edit screen for “Oil Flow Sensor ” the (+-)
buttons w ill allow the programmer to scroll and select betw een digital and analog. Once the
selection has been made, pressing the “Save” button w ill save the selection and return the
programmer back to the function screen allow ing the programmer to continue to the next
function or return to the main screen.

11.8 Phase Protection Reset


Three phase protection has been provided to protect the compressor against loss of phase
and phase symmetry. Nor mal panel mounted phase monitors only monitor pow er supplied
to the equipment. The ESC 201 provides protection to each compressor, monitoring the
pow er supplied through all electrical devices connected to the compressor motor. When the
compressor start sequence begins, the ESC 201 w ill w ait ½ second for the pow er to stabilize
and then check for pow er on all 3 phases and the proper sequence betw een phases. This
function can be configured for either automatic or manual reset. Factory default for this
function is “Autom atic”.

Autom atic Mode


During the operation of the compressor, if pow er is lost to any phase, the compressor w ill be
shut dow n immediately and the alar m “Phase Loss” w ill be displayed. The ESC 201 w ill
wait 30-seconds and attempt a compressor restart. The ESC 201 w ill attempt 3 restarts w ith
30-second delays betw een starts. If power has not returned after the three restarts, the time
delay betw een restarts will be increased to five minutes for two additional restarts. If all the
automatic restarts fail the compressor w ill be locked out requiring a manual reset.
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Preliminary Data Subject to change 4/22/02
Manual Mode
When phase protection is configured in the manual mode and pow er is lost to any phase, the
compressor w ill be shut dow n and locked off by the ESC 201, displaying the alar m “Phase
Loss”. Restarting the compressor requires depressing the manual reset button on the ESC.

Mode Programm ing


Changing the phase protection reset can be accomplished by follow ing steps 1-3 in section
5.0 to obtain the category selection screen, then follow the instruction found in section “11.0
Programm able Operations”. After accessing the edit screen for “Phase Loss Reset ” the
(+-) buttons w ill allow the programmer to scroll and select betw een automatic and manual.
Once the selection has been made, pressing the “Save” button w ill save the selection and
return the programmer back to the function screen allow ing the programmer to continue to
the next function or return to the main screen.

11.9 Pressure Transducer Type


The equipment discharge pressure will read from the equipment electronic pressure
transducer. This pressure will be used to make calculations in several ESC 201 functions.
Since several different type transducers are supplied the ESC 201 has the ability to read
these transducers once they are configured. Factory Default for this function is “Eclipse
500”.

Mode Programm ing


Changing the discharge pressure transducer type can be accomplished by follow ing steps 1-
3 in section 5.0 to obtain the category selection screen, then follow the instruction found in
section “11.0 Programm able Operations”. After accessing the edit screen for “Discharge
Transducer Type ” the (+-) buttons w ill allow the programmer to scroll and select betw een
several different types listed below . Once the selection has been made, pressing the “Save”
button w ill save the selection and return the programmer back to the function screen
allow ing the programmer to continue to the next function or return to the main screen.

Discharge Pressure Transducer Types

1. Eclipse 500 Lb
2. 4 – 20 ma 500 Lb
3. 0-10V 500 Lb
4. 1-6V 500 Lb
5. SA 500 Lb

11.10 Discharge Pressure Offset


The pressure transducer used for reading discharge pressure is a supplied component by the
manufacture of the electronic pressure controller. This function is designed to allow the ESC
201 pressure reading to be calibrated to the electronic pressure controller transducer. The
discharge pressure reading is used to calculate the low economizer function and the
differential pressure betw een discharge and suction for the analog oil flow sensor.

Discharge pressure offset function can only be accessed when the ESC 201 is setup as a
“Master Control”. The master control w ill send the discharge pressure values to the
connected slaves. The discharge pressure value can be read in the slave ESC 201 under the
“Discharge \ Suction Pressure” Function described under function 11.12

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Preliminary Data Subject to change 4/22/02
Mode programm ing
Changing the discharge pressure offset can be accomplished by follow ing steps 1-3 in
section 5.0 to obtain the category selection screen, then follow the instruction found in
section “11.0 Programm able Operations”. After accessing the edit screen for “discharge
pressure offset”, the (+-) buttons w ill allow the programmer to scroll up and dow n to place a
positive or negative value in the offset to correct the pressure value. Once the selection has
been made, pressing the “Save” button w ill save the offset value and return the programmer
back to the function screen allow ing the programmer to continue to the next function or
return to the main screen.

11.11 Suction Pressure Offset


The pressure transducer used for reading suction pressure is a supplied component by the
manufacture of the electronic pressure controller. This function is designed to allow the ESC
201 pressure reading to be calibrated to the electronic pressure controller transducer. The
suction pressure reading is used to calculate the differential pressure between discharge and
suction for the analog oil flow sensor.

Suction pressure offset function can only be accessed when the ESC 201 is setup as a
“Master Control”. The master control w ill send the suction pressure values to the connected
slaves. The discharge pressure value can be read in the slave ESC 201 under the “Discharge
\ Suction Pressure” Function described under function 11.12

Mode programm ing


Changing the suction pressure offset can be accomplished by follow ing steps 1-3 in section
5.0 to obtain the category selection screen, then follow the instruction found in section “11.0
Programm able Operations”. After accessing the edit screen for “suction pressure offset”,
the (+-) buttons w ill allow the programmer to scroll up and dow n to place a positive or
negative value in the offset to correct the pressure value. Once the selection has been
made, pressing the “Save” button w ill save the offset value and return the programmer back
to the function screen allow ing the programmer to continue to the next function or return to
the main screen.

11.12 Discharge \ Suction Pressure


This function can not be edited and is used to display the values read by the suction and
discharge pressure transducers. This function displays the discharge and suction pressure
values as determined by the discharge and suction pressure offsets. The slave ESC 201
receives these values from the master control across the Comm. 2 netw ork.

11.13 Motor Overload Monitor


The motor ther mistor w ill be read by the ESC 201 to determine if the motor temperature is
within the limits set by the manufacture. If the motor temperature exceeds these limits the
ESC 201 w ill shut dow n the compressor in either the automatic or manual mode.

This function is configured at the factory as “Enabled” when any Semi- Her metic
compressor is selected and “Disabled” when an open type is selected. Any time a Semi-
Her metic compressor is selected the motor overload configuration cannot be disabled.

Mode Programm ing


Changing the motor overload monitor can be accomplished by follow ing steps 1-3 in section
5.0 to obtain the category selection screen, then follow the instruction found in section “11.0
Programm able Operations”. After accessing the edit screen for “Motor Overload Monitor”,
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Preliminary Data Subject to change 4/22/02
the (+-) buttons w ill allow the programmer to scroll and select betw een Enable and Disable
for the open type compressor only. Once the selection has been made, pressing the “Save”
button w ill save the selection and return the programmer back to the function screen
allow ing the programmer to continue to the next function or return to the main screen.

11.14 Phase Monitor


The phase monitor function has the ability to be enabled or disabled depending on the
application and pow er source requirements. It is not recommended to disable this
function. Factory default for this function is “Enabled”.

Mode Programm ing


Changing the phase monitor can be accomplished by follow ing steps 1-3 in section 5.0 to
obtain the category selection screen, then follow the instruction found in section “11.0
Programm able Operations”. After accessing the edit screen for “Phase Monitor”, the (+-)
buttons w ill allow the programmer to scroll and select betw een Enable and Disable for the
open type compressor only. Once the selection has been made, pressing the “Save” button
will save the selection and return the programmer back to the function screen allow ing the
programmer to continue to the next function or return to the main screen.

11.15 Critical Discharge Monitor


If the discharge temperature exceeds 200°F the loaders w ill be deactivated, relieving some
of the load on the compressor. If the discharge temperature falls below 194°F, the Loaders
will be automatically activated.

When the compressor remains in this critical discharge temperature range (200°F/100°C to
211°F/99°C) for 20, minutes the compressor w ill be shut dow n in the automatic restart mode.
The compressor w ill restart and activate the loaders w hen the discharge temperature falls
below 194°F/90°C.

When the compressor is in the critical discharge temperature range the display w ill change
to “Critical Discharge Tem perature”. While the compressor is in the critical discharge
range, the
screen will only display the discharge temperature and no other compressor data, (w ith the
exception of the Jet Kool information if the compressor is configured as a “Master”). If the
temperature continues to rise to the high discharge cutout temperature of 212°F/100°C, the
screen will display “High Discharge Temperature” and the compressor w ill be shut dow n.
When in the high discharge temperature automatic mode the compressor w ill remain off until
the high discharge temperature reset point has been reached (approx 183°F/84°C), not the
critical discharge temperature reset point at 194°F/90°C.

11.16 7-Minute Time Delay


This function prevents short cycling that can cause damage to large compressor motors.
The SHM1-5000 to SHL1-7500 series compressor should not be cycled more than 7 times
an hour. This function is designed to reduce the number of short cycle starts, preventing
excessive overload conditions caused by short cycling. The factory default for the 7-minute
start delay is “Enabled”.

The timer is a 7- minute start to start operation, per mitting the compressor to start
immediately if the compressor has been either shut dow n for 7-minutes or constantly on for
7-minutes. If the compressor shuts down and attempts an immediate restart, the ESC 201
will delay the start for a period of 30-seconds. After this 30-second delay, the compressor

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Preliminary Data Subject to change 4/22/02
will be allow ed to start. If the compressor shuts down immediately for the second time, the
ESC 201 w ill keep the compressor off for the remainder of the 7-minutes or (6 minutes and
30 seconds at that point). The compressor must be either “ON” for 7 minutes or “OFF” for 7
minutes for the sequence to start over again.

The last line of the ESC 201 display w ill flash and alternate betw een the Jet Kool information
and the time remaining to start w hile in the starting count dow n mode. The operator w ill
know the exact time left before the compressor will start.

This function cannot be disabled on the SHM1-5000 to SHL1-7500 model compressors. The
SHM2 to SHL2 model compressors is the only series that this function can be disabled but is
not recommended.

Mode Programm ing


Changing the 7-minute time delay can be accomplished by follow ing steps 1-3 in section 5.0
to obtain the category selection screen, then follow the instruction found in section “11.0
Programm able Operations”. After accessing the edit screen for “7-Minute Time Delay” the
(+-) buttons w ill allow the programmer to scroll and select betw een Enable and Disable for
the SHM2 & SHL2 type compressors only. Once the selection has been made, pressing the
“Save” button w ill save the selection and return the programmer back to the function screen
allow ing the programmer to continue to the next function or return to the main screen.

11.17 Compressor Start Delay


Compressor start delay function is designed to prevent excessive current inrush to
equipment w ith multiple compressors. Most equipment w ith multiple compressors utilizes a
microprocessor to sequence the compressors, preventing a large inrush of current. If an
electronic failure occurs in the microprocessor, the compressors w ill lose sequence ability
provided by the microprocessor. The “Compressor Start Delay” function w ill act as a fail-
safe feature for this function. Factory default for this function is “0” seconds.

Each compressor can be programmed w ith an individual start time delay from 0 – 99
seconds. The programmer has the flexibility to program the compressor starts around their
system parameters to insure system safety, preventing long delays during nor mal starts.

Mode Programm ing


Changing the compressor start delay can be accomplished by follow ing steps 1-3 in section
5.0 to obtain the category selection screen, then follow the instruction found in section “11.0
Programm able Operations”. After accessing the edit screen for “Compressor Start Delay”,
the (+-) buttons w ill allow the programmer to scroll from 0 to 99 seconds. Once the start time
selection has been made, pressing the “Save” button w ill save the selection and return the
programmer back to the function screen allow ing the programmer to continue to the next
function or return to the main screen.

11.18 Temperature Probe Type


Tw o dif ferent temperature probes can be used for discharge temperature protection. The
PTC probe does not have the ability to be read for control and display purposes. The
PT1000 probe can be read, allow ing the ESC 201 to display the actual discharge
temperature of each compressor. Factory default for probe type is “PT1000”.

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Preliminary Data Subject to change 4/22/02
PTC
This probe has been used for many years as an on/off safety device monitored by many
different types of electronic controls to simply supply a signal for shutting dow n and
restarting the compressor w ithin a temperature range. This probe can be identified by
having either a metal flexible protection around the w ire w ith the markings PTC 100 stamped
into the probe housing or red rubber insulation w ith the mar kings PTC 100 stamped into the
housing. PTC probe can be used w ith the ESC 201 for discharge temperature protection by
simply selecting “ PTC” in the temperature probe type setup. This probe does not have the
ability to be read temperature, eliminating the possibility of displaying the discharge
temperature.

PT1000
Due to enhanced capabilities of the ESC 201 to monitor and control several functions, the
requirement of a readable probe w as essential. To operate the Jet Kool, Critical Discharge
Temperature, High Discharge Temperature and Low Discharge Temperature functions, the
PT 1000 temperature must be used. The PT 1000 can be read for display purposes and to
operate the above functions. A white insulated w ire w ith a yellow shrink band labeled
“PT1000” can identify this probe.

Mode Programm ing


Changing the temperature probe type can be accomplished by follow ing steps 1-3 in section
5.0 to obtain the category selection screen, then follow the instruction found in section “11.0
Programm able Operations”. After accessing the edit screen for “Temperature Probe
Type”, the (+-) buttons w ill allow the programmer to scroll betw een PTC and PT1000. Once
the proper selection has been made, pressing the “Save” button w ill save the selection and
return the programmer back to the function screen allow ing the programmer to continue to
the next function or return to the main screen.

11.19 Discharge Temperature Offset


This function provides the ability to calibrate the PT1000 discharge temperature probe. The
ability to calibrate the PT1000 can be accomplished in either a master or slave control.

Mode programm ing


Changing the discharge temperature offset can be accomplished by follow ing steps 1-3 in
section 5.0 to obtain the category selection screen, then follow the instruction found in
section “11.0 Programm able Operations”. After accessing the edit screen for “discharge
temperature offset”, the (+-) buttons will allow the programmer to scroll up and dow n to place
a positive or negative value in the offset to correct the temperature value. Once the selection
has been made, pressing the “Save” button w ill save the offset value and return the
programmer back to the function screen allow ing the programmer to continue to the next
function or return to the main screen.

11.20 Refrigerant Type


Refrigerant type is extremely important to setup in the ESC 201, since a calculation must be
performed using data in the pressure-temperature table for the refrigerants to calculate
condensing conditions. Refrigerant types to select from are R-22, R404A, R507, R134a,
R717 and None. Warning, if the correct refrigerant is not selected improper system
operation will occur. Factory default for this function is “R22”.

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Mode Programm ing
Changing the refrigerant type can be accomplished by follow ing steps 1-3 in section 5.0 to
obtain the category selection screen, then follow the instruction found in section “11.0
Programm able Operations”. After accessing the edit screen for “Refrigerant Type”, the (+-
) buttons w ill allow the programmer to scroll and select betw een the refrigerant types. Once
the selection has been made, pressing the “Save” button w ill save the selection and return
the programmer back to the function screen allow ing the programmer to continue to the next
function or return to the main screen.

11.21 Screen Contrast


Screen contrast can be made lighter or darker to enhance the display if the ESC 201 is
located in a light or dark area. By increasing or decreasing the number of bars displayed in
the function configuration the contrast w ill become lighter or darker. Factory default for this
function is “7 Bars”.

Mode Programm ing


Changing the screen contrast can be accomplished by follow ing steps 1-3 in section 5.0 to
obtain the category selection screen, then follow the instruction found in section “11.0
Programm able Operations”. After accessing the edit screen for “Screen Contrast”, the (+-)
buttons w ill allow the programmer to increase or decrease a bar indicator from 1 – 10 bars.
The more bars displayed the higher the contrast. Once the selection has been made,
pressing the “Save” button w ill save the selection and return the programmer back to the
function screen allow ing the programmer to continue to the next function or return to the
main screen.

11.22 Date & Time


The ESC 201 has an internal logging feature and the ability to tag alar ms w ith the current
time & date to be trans mitted across the 485 netw ork to other devices and controllers. It is
important the correct Date & Time be entered into the ESC 201.

The display screen has a date format of 02/10/01 and a time format of 15:20:36. The time is
displayed in Military Time (24 Hr Clock). Follow the instructions below to change the date &
time. Factory default for this function is the “Current Date & Time”.

Mode Programm ing


Changing the Date & Time can be accomplished by follow ing steps 1-3 in section 5.0 to
obtain the category selection screen, then follow the instruction found in section “11.0
Programm able Operations”. After accessing the edit screen for “Date & Time”, the (+-)
buttons w ill allow the programmer to scroll and change each group of the date or time. The
NEXT button w ill advance the cursor to the next group to allow the programmer to use the
(+-) buttons to change that group. Once the corrections have been made, pressing the
“Save” button w ill save the selection and return the programmer back to the function screen
allow ing the programmer to continue to the next function or return to the main screen.

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Preliminary Data Subject to change 4/22/02
11.23 Power Frequency
The ESC 201 is capable of operating w ith either 50 or 60 Hz pow er. The frequency can be
changed in the configuration mode to either 50 or 60 Hz by follow ing the below procedures.

Mode Programm ing


Changing the pow er frequency can be accomplished by follow ing steps 1-3 in section 5.0 to
obtain the category selection screen, then follow the instruction found in section “11.0
Programm able Operations”. After accessing the edit screen for “Pow er Frequency” the (+-
) buttons w ill allow the programmer to scroll betw een 50Hz and 60 Hz. Once the corrections
have been made, pressing the “Save” button w ill save the selection and return the
programmer back to the function screen allow ing the programmer to continue to the next
function or return to the main screen.

11.24 Jet Kool Source


Jet Kool oil cooler requires the discharge temperature as the input control source for the Jet
Kool system. This signal is read by the ESC 201 to operate the Jet Kool Valve (JKV 100).
The discharge temperature can be obtained by reading the individual compressor discharge
probes (PT1000 only) or a single probe mounted on the discharge header after the last
compressor and before the oil separator. Factory default for this function is
“Com pressors”.

Com pressors
When the ESC 201 is configured as “Compressors” in the Jet Kool Source mode, the
individual compressor discharge probes (PT1000 only) are read and averaged to deter mine
the overall rack discharge temperature. Any compressor in the averaging group that is not in
operation w ill be eliminated from the calculation process. Any time multiple suction groups
are used on a single discharge group w ith oil coolers supplying cool oil to the suction groups,
the configuration mode must be “ Compressors” and the PT1000 probe must be used as the
sensor device.

Rack Sensor
If the ESC 201 is operating an existing Jet Kool oil cooler w ith a probe mounted on the
discharge line, this probe can be used as long as the configuration mode has been set to
“Rack Sensor”. If the system w ill not per mit the use of the compressor probe, PT 1000 as
the source, a rack sensor probe must be used as the source.

Mode Programm ing


Changing the Jet Kool temperature source can be accomplished by follow ing steps 1-3 in
section 5.0 to obtain the category selection screen, then follow the instruction found in
section “11.0 Programm able Operations”. After accessing the edit screen for “Jet Kool
Temperature Source”, the (+-) buttons w ill allow the programmer to scroll betw een
Compressor and Rack Source. Once
the corrections have been made, pressing the “Save” button w ill save the selection and
return the programmer back to the function screen allow ing the programmer to continue to
the next function or return to the main screen.

(Cx) ESC ter minal number Page 33 of 67 ESC201C-4-23-02


Preliminary Data Subject to change 4/22/02
11.25 Language
Six languages can be programmed as screen displays. These languages are English,
Ger man, French, Spanish, Portuguese and Italian. These languages can be accessed
through the nor mal setup procedures found below in ”Mode Programming” or by using a the
follow ing short-cut. Factory default for this function is “English”.

1. Main Screen - press any button to access the “Setup ESC” Screen.
2. Setup ESC Screen - press the select button and the “Config” w ill begin to flash.
3. Press the “Next” button to scroll to “language”
4. When the “Language” is flashing press the pick button.
5. The choose language screen w ill appear.
6. press the edit button to access the languages.
7. Press the (+-) buttons to scroll betw een the languages.
8. When the desired languages appears, press the save button.
9. Press the “Menu” button and then the “Main” button to return to the main screen.

Mode Programm ing


Changing the Language can be accomplished by follow ing steps 1-3 in section 5.0 to obtain
the category selection screen, then follow the instruction found in section “11.0
Programm able Operations”. After accessing the edit screen for “Language”, the (+-)
buttons w ill allow the programmer to scroll betw een Languages. Once the corrections have
been made, pressing the “Save” button w ill save the selection and return the programmer
back to the function screen allow ing the programmer to continue to the next function or
return to the main screen.

11.26 Slaves on Line


This function can only be read in the master control. When accessing this function the total
number of slaves that are connect to the master on the Comm. 2 netw ork w ill be listed by their
ID numbers. This function can be used to deter mine if a problem exists w ith slaves
communicating to the master. Accessing the “Netw ork” function on the setup screen w ill
provide direct access to this function.

11.27 I.D. Network


The ESC 201 has the ability to communicate to a rack controller using an open protocol
across the 485 netw ork, and the N2 netw ork betw een the Master ESC and the Slave ESC
boards. The ESC 201 can be supplied w ith Echelon communications from the Master ESC
to the rack controller. To identify the slave ESC boards each ESC must be programmed
with an I.D. number. This I.D. Number must be set up in each ESC control. When multiple
compressors are configured w ith a master, the M aster ESC should be setup as # 1. The
I.D. number range starts at 0 and ends at 12. The slaves should be numbered from 2 –12.
The number 0 should be reserved for single compressor operations. Factory default for this
function is “0”.

Mode Programm ing


Changing the I.D. Netw ork source can be accomplished by follow ing steps 1-3 in section 5.0
to obtain the category selection screen, then follow the instruction found in section “11.0
Programm able Operations”. After accessing the edit screen for “I.D. Netw ork”, the (+-)
buttons w ill allow the programmer to scroll betw een number 0 and 12. Once the selection
has been made, pressing the “Save” button w ill save the selection and return the
programmer back to the function screen allow ing the programmer to continue to the next
function or return to the main screen.
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Preliminary Data Subject to change 4/22/02
11.28 EXT / ECH ID
The ESC 201 has the capability to transmit alar ms and operational data either directly across
the Comm.1 or Echelon Netw orks. This feature eliminates the use of additional input boards
and / or isolation relays to read the alarms generated by the ESC 201.

EXT
When this function is configured for EXT. ( External) the rack controller w ill be able to
communicate directly across the Comm. 1 netw ork to the ESC 201, retrieving all the alarm and
data logs. The manufacturer of the rack controller must provide the softw are to allow the rack
controller to read the ESC 201 alar ms and data. Protocol information to develop the softw are
is available by contacting the factory.

ECH
If the ESC 201 is utilizing Echelon communications the alar ms and data logs w ill be sent via
the Echelon netw ork. The information required to communicate across the Echelon netw ork
will be provided by the factory on request.

Mode Programm ing


Mode deter mination betw een the External or Echelon connections are determined by
connecting the communication w ires to either Comm.1 (RS-485) or Echelon ports. Do not
connect cables to both Comm. 1 and the Echelon ports. EXT/ECH configuration requires a
number from 1-31 in this field. This number is used to address the EXT/ECH function to
identify the Esc 201 on the Comm. 1 ( RS-485) netw ork. All master controls in the Echelon
netw ork must have the ECHELON FUNCTION “ Enabled” for the EXT/ECH function to operate
properly. IMPORTANT: The default setting for the EXT/ECH ID is “1”. This function m ust
be set to value great than “0” or the slave boards will not communicate to the m aster
ESC, causing problems w ith the Jet Kool, critical discharge tem perature and
econom izing functions.

Do not enable the ECHELON FUNCTION on the slave controllers.


The EXT/ECH function should not be confused w ith the I.D. Netw ork Function. When
programming the I.D. Netw ork, each Master ESC 201 w ill have slaves that are configured to
communicate to that Master ESC 201 for control purposes. The master w ill alw ays be
designated as “1” in the I.D. Netw ork (Function # 22) w ith slaves to follow as, 2,3,4 in that
group. Group #2 on the same equipment w ill have another master designated as “1” w ith it’s
slaves to follow as 2,3,4,5 in that group, and so on w ith group #3.

Note: A control designated as a master w ith a “1” in the I.D. Netw ork (#22) will also be
designed w ith sequential number from 1 to 31 in the EXT/ECH ID (# 23). The First Control in
the system w ill alw ays have an I.D. Netw ork as “1” w ith the EXT/ECH ID also as “1”. The first
control in the second group w ill have an I.D. Netw ork as “1” with the EXT/ECH ID as “5”.

Example: System w ith a total of 9 ESC 201 Controls configured w ith 3 groups w ith 4 Controls
in the first group, 3 controls in the second group, and 2 controls in the third group, w ill be set-
up as follow s:

(Cx) ESC ter minal number Page 35 of 67 ESC201C-4-23-02


Preliminary Data Subject to change 4/22/02
Control Number I.D. Netw ork EXT/ECH ID

Group #1
1 1 Master 1
2 2 Slave 2
3 3 Slave 3
4 4 Slave 4

Group # 2
5 1 Master 5
6 2 Slave 6
7 3 Slave 7

Group #3
8 1 Slave 8
9 2 Slave 9

Wiring Configuration
For External Connection

Comm. 1 Rack Controller


(RS-485)

Comm. 2 Comm. 2
Master Master
ESC 201 Comm. 1 ESC 201 Comm. 1
(RS-485) (RS-485)

Slave Slave Slave Slave Slave Slave


ESC 201 ESC 201 ESC 201 ESC 201 ESC 201 ESC 201

Comm. 2 Comm. 2

External Function Wiring


External Function w iring for the Comm.1 & Comm. 2 ports should be configured according to
the follow ing procedure.
Comm. 1 (RS-485)
A shielded cable should be daisy chain connected from the rack controller comm. Port to all
ESC 201 Comm.1 ports on the equipment.
Comm. 2 (RS-485)
A shielded cable should be daisy chain connected from the master ESC 201 Comm. 2 port to
all the slave Comm. 2 ports in the same group.

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Preliminary Data Subject to change 4/22/02
Echelon Function Wiring
Echelon Function w iring for Echelon & Comm. 2 ports should be configured according to the
follow ing procedure. The Echelon hardw are is a separate board mounted in the low er left
corner of the ESC 201 master control. Terminals to connect the w iring for the Echelon are
located on this daughter board. The Echelon daughter board plugs into the master ESC 201. If
the master must be replaced for any reason the Echelon board must be moved to the new
board.

Echelon
A shielded cable should be daisy chain connected from the rack controller Echelon port to all
Master ESC 201 Echelon ports.
Comm. 2
A shielded cable should be daisy chain connected from the master ESC 201 Comm. 2 port to
all the slave Comm. 2 ports in the same group.
Note: Make sure the Comm.1 (RS-485) ports are not w ired to the Echelon Ports.

Wiring Configuration
For Echelon Connections

Echelon Rack Controller


Echelon

Master Master
ESC 201 Echelon Board ESC 201 Echelon Board

Slave Slave Slave Slave Slave Slave


ESC 201 ESC 201 ESC 201 ESC 201 ESC 201 ESC 201

Comm. 2 Comm. 2

11.29 N2 network Mode


Three netw ork mode selections are possible w hen configuring the ESC 201. This
configuration must be properly set up to enable the logging of alar ms and information back
to the rack controller. Factory default for this function is “Slave”.

Master
The Master Mode is used w hen more than one ESC 201 is connected in the netw ork or
when Jet Kool oil cooling is required to be controlled. The master is the main
communication device betw een the slaves and the rack controller for alarms and other
information data. The master is also used to collect temperature data from the other
compressors to calculate the system discharge temperature to operate the Jet Kool oil
cooler. More than one master is possible to be set up on a large rack system w here multiple
Jet Kool oil coolers are used to control the different suction groups.

(Cx) ESC ter minal number Page 37 of 67 ESC201C-4-23-02


Preliminary Data Subject to change 4/22/02
Slave
Slave units are w ired in series to the master control using the N2 netw ork. The Comm. 2
connector is labeled (2+, 2-) on the bottom 2 ter minals of the 6 connector terminal plug,
located on the left
hand side of the ESC board. The slaves send the information collected from its compressor
across the N2 netw ork to the Master control.

Term inating Jumpers


Ter minating jumpers are located on the ESC 201 for Comm.1 and Comm.2. The alar m
boards are also equipped w ith a terminating jumper. The ter minating jumper must be placed
across the jumper pins on the last board in the netw ork. The Comm.1 netw ork is used to
connect the ESC master controls to the equipment controller. The ter mination jumper on
Comm.1 must be in place on the last ESC 201 in that netw ork. Comm.2 jumper is used on
the N2 netw ork w ith the slave and alar m boards. When the slaves are connected to the
master the Comm. 2 ter minating jumper must be in place on the last slave board or the last
alar m board in that group.

NOTE: The slave and alarm terminating jumpers perform the same function. The last board
in the netw ork must the ter minating jumper across the terminal pins. The Comm.1 & Comm.2
terminating jumpers are located on the low er left corner of the ESC 201, labeled
respectively.

11.30 Control By:


The screw compressors have two methods to be controlled by w hen using the ESC 201.
These methods are LOCAL and ECHELON. The Default control is by the local function.

Local Control
The local method of control consists of wiring through a computerized system controller, w hich
operates the compressors, and loaders using an electronic relay board. When the relay output
is energized it sends an electrical signal through a series of electro-mechanical safety devices
to the (C1) ter minal on the ESC 201 board. The ESC 201 recognizes this signal to start the
compressor and load the loaders. Any interruption in this (C1) signal w ill shut dow n the
compressors.

Echelon Control
Echelon method to control the compressors and loaders eliminates the electronic relay board.
The compressors and loaders are operated directly from the computer ized system controller
across the Echelon Netw ork. Elimination of the output relay board w ill simplify the unit w iring
and reduce the space requirements in the electrical panel. The (C1) input to the ESC 201 w ill
also be required as a safety monitor. An electrical signal is required to be sent through an on-
off switch to the standard high and low pressure safety switches, providing a mechanical back
up to the compressor. If this signal to ter minal ( C1) is broken for any reason the compressor
will be shut dow n.

11.31 Alarm Boards


ESC 201-alar m board mode must be configured as “Enabled” to communicate to the
designated board for the ESC.

(Cx) ESC ter minal number Page 38 of 67 ESC201C-4-23-02


Preliminary Data Subject to change 4/22/02
Mode Programm ing
Changing the alar m board mode can be accomplished by follow ing steps 1-3 in section 5.0
to obtain the category selection screen, then follow the instruction found in section “11.0

Programm able Operations”. After accessing the edit screen for “Alarm Boards”, the (+-)
buttons w ill allow the programmer to scroll betw een Enabled and Disabled. Once the
selection has been made, pressing the “Save” button w ill save the selection and return the
programmer back to the function screen allow ing the programmer to continue to the next
function or return to the main screen.

11.32 Echelon
Comm. 1 & 2 Ter minals
An optional Echelon card can be installed on the low er left
portion of the ESC 201. This card incorporates the hardw are
and software to provide Echelon communications. The
Echelon card is only required on the ESC 201 master control.
Information from the slave units w ill be trans mitted across the
N2 netw ork to the Echelon card and back to the equipment
controller. When using Echelon communication, the Echelon
mode must be enabled. The factory default for this
function is “Disabled”.
Echelon Port
Echelon Card

Mode Programm ing


Changing the Echelon Mode can be accomplished by follow ing steps 1-3 in section 5.0 to
obtain the category selection screen, then follow the instruction found in section “11.0
Programm able Operations”. After accessing the edit screen for “Echelon”, the (+-) buttons
will allow the programmer to scroll betw een enabled and disabled. Once the selection has
been made, pressing the “Save” button w ill save the selection and return the programmer
back to the function screen allow ing the programmer to continue to the next function or
return to the main screen.

11.33 Temperature
The screen display for temperature can be changed from Fahrenheit to Centigrade. The
factory default for this function is “Fahrenheit”.

Mode Programm ing


Changing the temperature units can be accomplished by follow ing steps 1-3 in section 5.0 to
obtain the category selection screen, then follow the instruction found in section “11.0
Programm able Operations”. After accessing the edit screen for “Temperature”, the (+-)
buttons w ill allow the programmer to scroll betw een Fahrenheit and Centigrade. Once the
selection has been made, pressing the “Save” button w ill save the selection and return the
programmer back to the function screen allow ing the programmer to continue to the next
function or return to the main screen.

(Cx) ESC ter minal number Page 39 of 67 ESC201C-4-23-02


Preliminary Data Subject to change 4/22/02
11.34 Pressure
The screen display for Pressure can be changed from PSI to Bars. The factory default for
this function is “PSI”.

Mode Programm ing


Changing the pressure units can be accomplished by follow ing steps 1-3 in section 5.0 to
obtain the category selection screen, then follow the instruction found in section “11.0
Programm able Operations”. After accessing the edit screen for “Pressure” the (+-) buttons
will allow the programmer to scroll betw een PSI and Bars. Once the selection has been
made, pressing the “Save” button w ill save the selection and return the programmer back to
the function screen allow ing the programmer to continue to the next function or return to the
main screen.

11.35 Flow Rate


The screen display for Flow Rate can be changed from Gallons/Min to Liters/Min. The
factory default for this function is “Gallons/Min”.

Mode Programm ing


Changing the flow rate can be accomplished by follow ing steps 1-3 in section 5.0 to obtain
the category selection screen, then follow the instruction found in section “11.0
Programm able Operations”. After accessing the edit screen for “Flow Rate”, the (+-)
buttons w ill allow the programmer to scroll betw een Gallons/Min and Liters/Min. Once the
selection has been made, pressing the “Save” button w ill save the selection and return the
programmer back to the function screen allow ing the programmer to continue to the next
function or return to the main screen.

11.36 Date Format


The date format on the screen display can be change to accommodate the U.S. format and
the European For mat. The U.S. For mat is displayed as “Month/Day”, w hile the European is
“Day/Month”. The factory default for this function is “Month/Day”.

Mode Programm ing


Changing the date format can be accomplished by follow ing steps 1-3 in section 5.0 to
obtain the category selection screen, then follow the instruction found in section “11.0
Programm able Operations”. After accessing the edit screen for “Date For mat”, the (+-)
buttons w ill allow the

programmer to scroll betw een Month/Day and Day/Month. Once the selection has been
made, pressing the “Save” button w ill save the selection and return the programmer back to
the function screen allow ing the programmer to continue to the next function or return to the
main screen.

12.0 Memory Chip


The ESC 201 is equipped w ith a non-volatile memory chip. This memory chip is an electrical
erasable programmable memory (EEPROM). This chip is located under the display module
labeled as U5. The EEPROM w ill hold the programmable configuration setting for the
compressor. The EEPROM can be removed from one control and placed in another control to
provide the user w ith the ability to transfer the compressor setting w ithout reprogramming the
ESC 201. Earlier versions of the control w ere equipped w ith an iButton located on the low er
left-hand corner of the ESC 201. The iButton looks like a small battery mounted in a w ell and
held in place w ith a heavy spring clip. The iButton is a programmable chip used to store
(Cx) ESC ter minal number Page 40 of 67 ESC201C-4-23-02
Preliminary Data Subject to change 4/22/02
information similar to the function of the EEPROM. Due to various constrains of the iButton, it
did not w ork as an acceptable method to store the programmable memory. If the iButton can
not be visibly located on the low er left corner of the board directly above the rest button, the
control has been configured w ith an EEPROM.

Exchanging the EEPROM


To exchange the EEPROM from one control to another, remove all pow er from the board by
unplugging both connectors labeled “C” and the 24 volt pow er plug labeled “AC , +-1, +-2”.
Remove the metal cover by removing the 3-5/16 nuts. The next step is to remove the four
screws holding the display module. Hold the display from the top and bottom on the left side of
display and gently pull on the display w ith an up and dow n motion to remove the display from
the socket. The EEPROM is located under the display in the upper right corner mar ked on the
board as U5. Place a small screwdriver between the EEPROM and the socket and gently pry
up on the EEPROM. When replacing the EEPROM make sure the pins are aligned properly
before pushing the EEPROM into the socket. Proper alignment of the display is crucial to the
operation of the display, make sure the display pins are correctly aligned w hen plugging in the
display to avoid any problems the display operation. Replace all screws, nuts and covers
before plugging in the pow er connectors.

Alarm Dry Pow er


13.0 Alarm Boards Designation Contact Ter minal
Dirty Filter D1 H1
The N2 netw ork is also used to
communicate to the ESC 201 alar m Motor Winding Overload D2 H2
boards. The ESC 201 is equipped w ith Oil Flow D3 H3
one alar m output for a general alar m. Oil Level D4 H4
If a customer requires specific alarms, Discharge Gas D5 H5
logging can be accomplished w ith an Phase D6 H6
alar m board to either the rack controller Rotation-Wrong Sequence D7 H7
or an alar m system. The alar m board Run Proof / Bypass D8 H8
is configured w ith an N2 connector for Over Discharge Limit D9 H9
netw orking to the ESC 201 boards. Low Discharge Temp D10 H10
The alar m signal is sent out across this
Digital Alarm Common D11 -
N2 netw ork to activate the alar m
module. When the alar m module Alarm Output Supply Voltage - H11
receives the signal for an individual
alar m, the board closes the related
contacts to generate the alar m. The N2 connector labeled (Comm. 2) is located on the low er
left portion of the board to the right of the 4-position dipsw itch. Located to the right of the
Comm. 2 port is the ter minating jumper. If it is the
last board in the communication chain, then the
jumper must be placed over the tw o pins (J2).

A non-center tapped 24VAC transformer pow ers


the alar m board. The pow er requirement for each
board is 15VA. The 24VAC-pow er supply is
connected to the 2-pin connector on the low er left
corner of the board labeled 24Vac. Tw o (2)
contacts are provided for each alarm point. One is
a dry set of contacts on terminal block 2
(TB2) providing a closure to signal another device as an alar m, and a voltage output set on
terminal block 1 (TB1), nor mally used for panel lights. The voltage contacts can be utilized
(Cx) ESC ter minal number Page 41 of 67 ESC201C-4-23-02
Preliminary Data Subject to change 4/22/02
with some controllers that accept a voltage input for alarms rather than a dry contact closure.
The table to the r ight shows a schedule of alarm and ter minal designations for both the dry
and pow er terminals.

Alarm Board I.D.


The table show n in this section illustrates the sw itch positions to address the alarm boards.
The “OFF” position for the sw itch is “UP”. To place the sw itch “ON” the sw itch must be in
the “DOWN” position. The designation of the alar m board I.D. must correspond to the ESC
201 transmitting the alar m message. Example: if the ESC 201 has an I.D. of “1” the alar m
board receiving the information must also an I.D. of “1”. Duplicate I.D. numbers are possible
on large systems w here more than one Master ESC 201 is required. When this type of
address scheme is used, the Master, slave and alarm boards must remain in a w iring group.
The green LED light located in the middle right side of the board is the pow er light, indicating
the unit has pow er when lit. The green lights next to the Comm. 2 port are communication
lights, w hich will flash w hen communicating w ith the ESC 201.

Alarm Board Wiring


Shielded cable must be used to connect the N2 netw ork and the 24 VAC pow er connections.
One end of the shield must be attached to ground. Wir ing the dry outputs to another input
device should also be w ired using shielded cable, unless the manufacture of the input device
instructs differently. High voltage output from TB1 can be w ired according to standard w iring
practices. Shielded cable, w ith one end of the shield grounded, w ill reduce the
possibility of noise transmission to the alarm and ESC 201 boards.

When more than one master


ESC201 is used in a system w ith a Associated ESC
single rack controller, the alar m ID SW5-1 SW5-2 SW5-3 SW5-4
boards should only be w ired to that
group of master and slave boards.
None OFF OFF OFF OFF
Each time a new master is used, the
address numbering scheme for ESC 1 ON OFF OFF OFF
201 and alar m boards w ill start back 2 OFF ON OFF OFF
at “1”. 3 ON ON OFF OFF
4 OFF OFF ON OFF
14.0 Remote Reset 5 ON OFF ON OFF
Remote reset can be accomplished 6 OFF ON ON OFF
by w iring the equipment controller 7 ON ON ON OFF
output relay betw een terminals (A6) 8 OFF OFF OFF ON
and (A7). When the equipment 9 ON OFF OFF ON
controller is equipped w ith a phone 10 OFF ON OFF ON
modem, the 11 ON ON OFF ON
12 OFF OFF ON ON
operator accesses the output sw itch
13 ON OFF ON ON
wired to (A6 & A7). Closing and
opening the sw itch w ill reset the 14 OFF ON ON ON
ESC 201. Note: the output sw itch 15 ON ON ON ON
must be opened, since the activation of the remote rest is predicated on the opening not the
closing of the sw itch.

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Preliminary Data Subject to change 4/22/02
15.0 Manual Reset
The manual reset button is located on the low er portion of the ESC 201 to the left of the
green LED pow er light. This button w ill allow the operator to clear all alar ms and restart the
compressor.

16.0 Logging
The ESC 201 has a per manent memory that w ill log the follow ing functions. This logged
data can be accessed by the use of a Prolink module and the required softw are. This
memory can be accessed but not erased.

Logged Functions: 1. Oil Failure


2. Motor Overload
3. Discharge Temperature
4. Rotation
5. Compressor Starts

The Prolink and softw are are optional accessories and can purchased via normal
distribution.

17.0 ESC 200 upgrade to ESC 201


The ESC 200 screw controller can be replaced and upgraded to the ESC 201 w ith a few
Modifications. To change out an ESC 200 and replace the control w ith an ESC 201, follow
these steps.

17.10 Removing the ESC 200

1. Unplug all the ter minal plugs on the Esc 200.


2. Mark the three phase w ires to be placed in the same position on the ESC 201.
3. Disconnect the three phase w ires.
4. Remove the ESC 200 from the snap track.

17.20 Installing the ESC 201

1. Place the ESC 201 in the snap track, positing the control close to the old terminal plugs.
2. Connect the phase w ires in the same position as the ESC 200.
3. Remove the control w ires from the ESC 200 ter minal plugs and w ire them on the new
terminal plugs of the ESC 201 per the w iring schematic in Appendix G.
4. Im portant: The Esc 201 requires a 24VAC transformer w ithout a center tap ground
connection. The pow er requirement w ill be different depending the controls operation w ith
or w ithout Jet Kool.
Transformer w ithout Jet Kool & Echelon - 24VAC, 16VA
Transformer w ith Jet Kool & Echelon - 24VAC, 22VA
If ESC 200 and ESC 201 controls are both used on the same equipment they w ill require
different pow er supplies. Suggestion, a transformer that can handle multiple ESC 201
controls maybe the best alternative for expansion or future replacement purposes.

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Preliminary Data Subject to change 4/22/02
17.30 ESC 200 Alarm Function to ESC 201 Alarm Boards
1. The ESC 201 has a provision for one high voltage alar m output to illuminate a panel light. If
the alar m outputs from the ESC 200 are required by the customer, an ESC 201 alar m board
can be purchased to display all the existing alar ms lights.
2. If the system requires the use of only one alar m panel light, the present alar m lights can be
eliminated by using the alar m output on ter minal C10 of the ESC 201, calling it a “General
Alarm”, illuminating one of the existing lights to indicate an alar m has occurred. The alar m
can then be read on the ESC 201 display.
3. Installation of the ESC 201 alar m board w ill require additional panel space of approximately
6” X 8”. Each alar m board requires 15VA pow er at 24VAC, as w ell as, shield cable
connections betw een the comm. 2 netw orks of the alarm board and the ESC 201. The
board provides for 10 high voltage and 10 digital outputs to operate panel lights and low
voltage signals to the rack controller for remote alar ms.

4. Listed below are the terminal relationships from the high voltage ter minals on the ESC 200
to the high voltage ter minals on the Esc 201 alar m board.

Description ESC 200 ESC 201


Outputs Outputs

1. Dirty Oil Filter Alar m D1 H1


2. Motor Winding Overload Alar m D2 H2
3. Oil Flow Alarm D3 H3
4. Oil Level Alar m D4 H4
5. High Discharge Gas Alar m D5 H5
6. Phase Loss Alarm D6 H6
7. Rotation / Wrong Sequence D7 H7
8. Run Proof / By-Pass Alarm D8 H8
9. Over Discharge Limit D9 H9
10. Low Discharge Temperature D10 H10

5. When w iring alarm board please refer to section 13.0 “Alarm Board I.D. and w iring”.
Appendix F, “ ESC 201 alar m board w iring” can also be used as a guide.

(Cx) ESC ter minal number Page 44 of 67 ESC201C-4-23-02


Preliminary Data Subject to change 4/22/02
Appendix A

Compressor Motor – Phase - Run Proof Configurations

COMPRESSOR
COMPRESSOR CIRCUIT
CIRCUIT BREAKER
BREAKER

L1 POWER
LINE VOLTAGE
DISTRIBUTION
120 OR 208-230 VAC
L1 L2 L3 BLOCK
(IF REQUIRED)
COMPRESSOR
CONTACTOR L1 POWER
LINE VOLTAGE
120 OR 208-230 VAC
ESC 201
AUXILIARY

COMPRESSOR COMPRESSOR
COIL

BYPASS OR PRIMARY SECONDARY


DIRECT ON LINE CONTACTOR CONTACTOR
RUN PROOF

C4 ESC 201

AUXILIARY

AUXILIARY
L1 L2 L3
L1 L2 L3

COIL

COIL
C C
FUSES BYPASS OR
T1 T2 T3 T1 T2 T3 DIRECT ON LINE
PHASE C RUN PROOF

C4
PHASE B
FUSES
PHASE A
FURNAS 958 PHASE C
ELECTRONIC
PHASE B
OVERLOAD
PHASE A
FURNAS 958 FURNAS 958
95 96 ELECTRONIC ELECTRONIC
OVERLOAD OVERLOAD
REQUIRED FOR 95 96 95 96
40 H.P. & ABOVE - LOW TEMP.
50 H.P. & ABOVE - MED. TEMP.
REQUIRED FOR REQUIRED FOR
40 H.P. & ABOVE - LOW TEMP. 40 H.P. & ABOVE - LOW TEMP.
50 H.P. & ABOVE - MED. TEMP. 50 H.P. & ABOVE - MED. TEMP.

T1

1
T1 7

T2
T2

COMPRESSOR COMPRESSOR
TERMINAL BOX
TERMINAL BOX
(SINGLE VOLTAGE) (SINGLE VOLTAGE)

Direct On Line Part Winding Start


COMPRESSOR
CIRCUIT
BREAKER

L1 POWER
OUTPUT RELAY

L1 L2 L3
RUN PROOF

LINE VOLTAGE
120 OR 208-230 VAC INVERTER
ESC 201

COMPRESSOR T1 T2 T3 INVERTER
COMPRESSOR
BYPASS RUN PROOF
INVERTER
CONTACTOR A4
CONTACTOR
A7
AUXILIARY
AUXILIARY

L1 L2 L3 L1 L2 L3
COIL

COIL

C C
T1 T2 T3 T1 T2 T3 BYPASS OR
DIRECT ON LINE
RUN PROOF
C4
FUSES

PHASE C

PHASE B

PHASE A

FURNAS 958
ELECTRONIC
OVERLOAD
REQUIRED FOR
95 96 40 H.P. & ABOVE - LOW TEMP.
50 H.P. & ABOVE - MED. TEMP.

Inverter
T1
1
7

2
8
COMPRESSOR
TERMINAL BOX
3
9
(SINGLE VOLTAGE)
T2

(Cx) ESC ter minal number Page 45 of 67 ESC201C-4-23-02


Preliminary Data Subject to change 4/22/02
Appendix B

Compressor Configurations
Figure # 1
SHM2 to SHL2
SDM1-0084 to SDL1-0118
Front View
Rotation Switch
THE ROTATION SWITCH MUST BE
INSTALLED IN THE VERTICAL
ROTATION
SWITCH POSITION
860-1266-06

Figure # 2
3/8" N.P.T.
VIBRATION DAMPER SHM2-SHL2
1/8" N.P.T.
BRASS STREET EL SDM1-0084 to SDL1-0118
Side View
CR1 CR2
3/8" N.P.T. PLUG
REMOVE AND DISCARD

1/4" N.T.P. PORT


FOR HIGH PRESSURE
CONTROL CONNECTION

Figure # 3
SHM1-5000 to SHL1-5000
Front View

CR1
CR2 Rotation Switch
THE ROTATION SWITCH MUST BE
INSTALLED IN THE VERTICAL
3/8" F.P.T. X 3/4" M.P.T. POSITION
HEX BUSHING
1/8" N.P.T.
BRASS STREET EL

3/8" N.P.T.
VIBRATION DAMPER

3/4" N.P.T. PLUG


REMOVE AND DISCARD

Economizer Port

CR2 CR1
Rotation Switch
1/4" N.P.T. PORT
THE ROTATION SWITCH MUST BE
FOR HIGH PRESSURE
INSTALLED IN THE VERTICAL
CONTROL POSITION
3/8" N.P.T.

Figure #4 VIBRATION DAMPER


1/8" N.P.T.

SHM1-7000 to SHL1-7500 BRASS STREET EL

SDM1-0165 to SDL1-0250
Front View
3/8" N.P.T. PLUG

REMOVE AND DISCARD

(Cx) ESC ter minal number Page 46 of 67 ESC201C-4-23-02


Preliminary Data Subject to change 4/22/02
Appendix C

Electrical Wiring and Power Specifications


1. High Voltage

Pow er Voltage
208 – 480 VAC 3 φ
Ter minal Block – 3 positions
Voltage Rating 600 VAC
Current Draw , 0.5 mA Ac
Voltages are referenced phase to phase

Control Voltage
C1- Compressor Control (on/off)
C2- Capacity Regulator #1 (on/off)
C3- Capacity Regulator (on/off)
Voltage 120/208/240 VAC
Ter minal Block Rated 240VAC
Current Draw 0.5 mA Ac

Pow er Input and Serial Communication


TB1-1. RS-485 Comm2(-)
TB1-2. RS-485 Comm2(+)
TB1-3. RS-485 Comm1(-)
TB1-4. RS-485 Comm1(+)
TB1-5. AC 24 VAC
TB1-6. AC 24VAC
Fuse 3A
Operating Current 760 mA AC
Maximum Current 900 mA AC
Maximum Pow er requirement
With Jet Kool & Echelon- 22VA
Without Jet Kool & Echelon- 16VA
Ter minal Block, 6-position, 240 VAC

Alarm and Control Outputs


C4- Direct on Line Run Proof - Input, 120 VAC
C5- Compressor Output
C6- Part Winding Start Output
C7- Capacity Regulator #1 Output
C8- Capacity Regulator #2 Output
C9- Oil Solenoid Output
C10- Alar m Output
C11- Economizer Output
C12- Control Output and Alar m Relay Common – 5A fused
Ter minal Block,8-position, 240VAC

(Cx) ESC ter minal number Page 47 of 67 ESC201C-4-23-02


Preliminary Data Subject to change 4/22/02
Appendix C (cont)
Electrical Wiring and Power Specifications

2. Low Voltage

Input Signals (Digital)


A1- Dirty Oil Filter
A2- Oil Level
A3- Rotation
A4- Inverter Run Proof
A5- Oil Flow
A6- Remote Alarm Reset
Max Voltage Output 5V DC
A7- Input Ground
Max. Input Voltage Input 5V DC- from A1-A6
A8- +15VDC Sensor Supply
Regulated +-5%, not to exceed 50mADC total

Input Signals (Analog)


B1- Motor Overload
PTC ther mistor cut-out - 4.5k Ω and cut-in -2.75KΩ
B2- Discharge Gas Temperature
PTC 100 cut-out =1385Ω and cut-in = 1309Ω
PT1000
B3- Jet Kool Temperature
B4- Discharge Pressure
B5- Suction Pressure
B6- Oil Flow -Analog
B7- Input Ground –Analog
B8- +5VDC Sensor Pow er +-5%, not to exceed 150 mA total
Ter minal Block- 8 position, 240VAC

(Cx) ESC ter minal number Page 48 of 67 ESC201C-4-23-02


Preliminary Data Subject to change 4/22/02
Appendix D
Com pressor Control Diagram

24 VAC
TRANSFORMER
SHIELDED CABLE

L L

ESC 201
POWER
AC AC

GND

ESC 201
COMPRESSOR CONTROL INPUT C1
208-230 OR 115 VAC
LINE VOLTAGE
LOADER #1 CONTROL INPUT C2
L1
INVERTER BYPASS LOADER #2 CONTROL INPUT C3
CONTACTOR
AUXILIARY
INVERTER BYPASS RUN PROOF INPUT
C4
INVERTER (DIRECT ON LINE RUN PROOF INPUT)
BYPASS
RUN PROOF CONTROL AND ALARM INPUT C12
VOLTAGE (L1)
DOS
BLK WHT DIRTY OIL
3 A1
DIRTY OIL FILTER FILTER INPUT
SAFETY SWITCH
OLS
BLK WHT OIL LEVEL INPUT
3 A2
OIL LEVEL
SWITCH RED +5 VDC AUXILIARY OUTPUT / OIL LEVEL
B8

CRS COMPRESSOR ROTATION INPUT


BLU BLU
3 A3
ROTATION INVERTER
SWITCH PROOF
3
INVERTER RUN
PROOF INPUT A4 C5 COMPRESSOR OUTPUT
INVERTER
RUN PROOF

OFS
3
BRN BLU DIGITAL OIL FLOW INPUT C6 PART WINDING OUTPUT
A5
OIL FLOW
SWITCH
REMOTE ALARM RESET INPUT C7 LOADER #1 OUTPUT
3 A6
REMOTE ALARM
RESET OUTPUT
DIGITAL INPUT COMMON / GROUND C8 LOADER #2 OUTPUT
3 A7
NOTE:
IT IS VERY IMPORTANT FOR THE
CORRECT OPERATION OF THE
ESC 201 THAT THIS GROUND C9 OIL SOLENOID OUTPUT
CONNECTION IS PROPERLY WIRED.
MOTOR OVERLOAD
CMT
INPUT
4 T1 T2 B1 C10 ALARM OUTPUT
CDT MOTOR
DISCHARGE
BRN BLU THERMISTORS TEMPERATURE
4 B2 C11
INPUT ECONOMIZER OUTPUT
DISCHARGE
GAS THERMISTOR JKT
4 JET KOOL TEMPERATURE B3
INPUT
JET KOOL
TEMPERATURE SENSOR
0 - 500 B4
DISCHARGE PRESSURE INPUT
RACK DISCHARGE
TRANSDUCER
0 - 100 B5
SUCTION PRESSURE INPUT
RACK SUCTION
TRANSDUCER
OFT
4 OIL FLOW B6
TRANSDUCER INPUT
OIL FLOW
TRANSDUCER
A8
+15 VDC AUXILIARY OUTPUT
4 B7
ANALOG INPUT COMMON / GROUND
ESC 201
PHASE CONNECTIONS
NOTE:
IT IS VERY IMPORTANT FOR THE PHASE PHASE PHASE
CORRECT OPERATION OF THE
ESC 201 THAT THIS GROUND A B C
CONNECTION IS PROPERLY WIRED.

ESC 201
PHASE CONNECTIONS
LINE VOLTAGE WIRED
FROM THE LOAD SIDE
OF THE COMPRESSOR
CONTACTOR
REV 'A' ESC-201B

(Cx) ESC ter minal number Page 49 of 67 ESC201C-4-23-02


Preliminary Data Subject to change 4/22/02
Appendix E
System Wiring Diagram

230/60/1Ø

COMPRESSOR #1 CONTROL POWER

1 BLACK 2 RED

ENCORE MANUAL RESET


STARTER MICRO-SET HIGH PRESSURE
BOARD 1 LOW PRESSURE
ESW 104 ORANGE/BLK RELAY 1 105 PURPLE/WHT OVERLOAD 116 ORANGE/WHT 117 BROWN/WHT CONTROL
CONTROL
1 16 17

COMPRESSOR 95 96
COMPRESSOR CONTROL 958EA32A
ON - OFF SWITCH
P170AB-12C P100DC-3C

118 RED/WHT STRIPE


COMPRESSOR 1 RUN PROOF CONTACT
WIRED TO ENCORE PERFORMER
DIGITAL INPUT BOARD 3 18
DIGITAL INPUT 1

INPUT 1 COM
130 ORANGE/BLK

131 PURPLE 2 RED

COMPRESSOR 1
CONTACTOR ESC 201
AUXILIARY MASTER UNIT
COMPRESSOR #1
CONTACTOR

C1 C5 19 C 2
CONTROLLER
BOARD 1 119 BLUE/BLK ECONOMIZER
RELAY 2
LOADER #1 CONTROL LIQUID VALVE G
C2

101 PURPLE/WHT

1 BLACK CONTROLLER
BOARD 1 COMPRESSOR
G LOADER #1 VALVE

LINE VOLTAGE INPUTS


RELAY 3
LOADER #2 CONTROL
C3

COMPRESSOR 1 102 PURPLE/BLK C7 20 2

CONTACTOR 120 YELLOW


AUXILIARY
COMPRESSOR G
C4
LOADER #2 VALVE
COMPRESSOR 1
RUN PROOF 103 BLUE/WHT

LINE VOLTAGE OUTPUTS


C8 21

C12 121 YELLOW/BLK


1 BLACK G
OIL SOLENOID VALVE

DOS WHT C9 22 2
BLK 106 BROWN
3 6 A1 122 PINK/BLK
DIRTY OIL FILTER COMPRESSOR 1 G
106 BROWN
SAFETY SWITCH ESC 201 ALARM

C10 R
BLK WHT
OLS
123 YELLOW ECONOMIZER
3 7 A2
SOLENOID VALVE
RED 7 PURPLE
OIL LEVEL
C11
SWITCH 25 B8 24
(MASTER ESC-201 ONLY)
25 BLUE
124 RED/BLK
G
DIGITAL INPUTS

BLU CRS BLU


CMT
3 8 A3 T2 T1
B1 4
COMPRESSOR 108 WHITE 12
ROTATION SWITCH
COMPRESSOR
112 GRAY/WHT MOTOR THERMISTORS
SHIELD
BRN BLU CDT
OFS RED
WHT
3 10 A5 B2 13
4
110 GRAY
113 ORANGE COMPRESSOR DISCHARGE
ANALOG INPUTS

CONTROLLER OIL FLOW GAS THERMISTOR


SWITCH
BOARD 6 (PT 1000)
RELAY 3 DISCHARGE PRESSURE INPUT
B4 0 - 500
3 11 A6 (MASTER ESC-201 ONLY)
RACK DISCHARGE
REMOTE ALARM RESET
111 ORANGE/BLK TRANSDUCER

-30° SUCTION PRESSURE INPUT


B5 0 - 100
A7
(MASTER ESC-201 ONLY)
DIGITAL INPUT COMMON / GROUND RACK SUCTION
GREEN
NOTE: TRANSDUCER

B7
IT IS VERY IMPORTANT FOR THE ANALOG INPUT COMMON / GROUND
CORRECT OPERATION OF THE GREEN/WHT

ESC 201 THAT THIS GROUND


NOTE:
CONNECTION IS PROPERLY WIRED.
IT IS VERY IMPORTANT FOR THE
CORRECT OPERATION OF THE

ESC 201 THAT THIS GROUND

CONNECTION IS PROPERLY WIRED.

ESC201-M.WMF

(Cx) ESC ter minal number Page 50 of 67 ESC201C-4-23-02


Preliminary Data Subject to change 4/22/02
Appendix F
ESC 201 Alarm Board

TRANSFORMER
24 VAC ESC 201

ESC 201 (N2) 120 OR 208-230/60/1Ø


NETWORK COMMUNICATION
"DAISY CHAINED" TO ALL CONTROL POWER
ESC 201'S & ALARM BOARDS

15 VA MAX
24 VAC
AC

AC
1 BLACK 2 RED

ESC 201 (N2)


NETWORK COMMUNICATION

COMM2
+
"DAISY CHAINED" TO ALL
ESC 201'S & ALARM BOARDS -

DIGITAL INPUTS
TO CONTROLLER HIGH VOLTAGE H11
INPUT BOARD COMMON 2 RED

D1 H1 R

DIRTY OIL FILTER ALARM


DIRTY OIL FILTER ALARM

D2 H2 R

MOTOR OVERLOAD ALARM MOTOR OVERLOAD ALARM

D3 H3 R

OIL FLOW ALARM OIL FLOW ALARM


DIGITAL ALARM OUTPUTS

LINE VOLTAGE OUTPUTS

D4 H4 R

OIL LEVEL ALARM OIL LEVEL ALARM

D5 H5 R

DISCHARGE GAS ALARM DISCHARGE GAS ALARM

R
D6 H6
PHASE ALARM PHASE ALARM

D7 H7 R

ROTATION / WRONG
SEQUENCE ALARM ROTATION / WRONG SEQUENCE ALARM

D8 H8 R

RUN PROOF / RUN PROOF / BYPASS ALARM


BYPASS ALARM

D9 H9 R

OVER DISCHARGE OVER DISCHARGE LIMIT ALARM


LIMIT ALARM

D10 H10 R

LOW DISCHARGE
LOW DISCHARGE TEMP. ALARM
TEMPERATURE ALARM
DIGITAL
ALARM
D11
COMMON

USE COPPER CONDUCTORS ONLY

TIGHTEN ALL ELECTRICAL CONNECTIONS BEFORE POWER IS APPLIED.

USE #14 THHN MINIMUM FOR FIELD CONNECTIONS UNLESS OTHERWISE NOTED.

ALL WIRING MUST BE DONE IN ACCORDANCE TO NATIONAL ELECTRIC CODE.

USE CLASS 1 WIRING METHODS FOR ALL CONTROL FIELD CONNECTIONS.

FIELD WIRING

(Cx) ESC ter minal number Page 51 of 67 ESC201C-4-23-02


Preliminary Data Subject to change 4/22/02
Appendix G
ESC 200 Conversion to ESC 201

Legend 24 VAC
Symbol desinated ESC 200 terminal connection point TRANSFORMER
SHIELDED CABLE
Notes
1. Digital input grounds are connected to ESC 201 termianl A7 L L
2. Analog input groungs are connected to ESC 201 terminal B7
3. Oil output (C9) and Economizer output (C11) functions on the ESC 201
ESC 201
POWER
are separate terminal points. Since the functions are combined AC
on the same terminal point (C7) on the ESC 200 make sure the AC
proper wire for each function on the ESC 200 are connected GND
to the correct positions on the ESC 201.
ESC 201/200
COMPRESSOR CONTROL INPUT C1 C1
208-230 OR 115 VAC
LINE VOLTAGE
LOADER #1 CONTROL INPUT C2 C2
L1
INVERTER BYPASS LOADER #2 CONTROL INPUT C3 C3
CONTACTOR
AUXILIARY
INVERTER BYPASS RUN PROOF INPUT
C4 A6
INVERTER (DIRECT ON LINE RUN PROOF INPUT)
BYPASS
RUN PROOF CONTROL AND ALARM INPUT C12 C8
VOLTAGE (L1)
DOS
BLK WHT DIRTY OIL
3 A1 A1
DIRTY OIL FILTER FILTER INPUT
SAFETY SWITCH
OLS
BLK WHT OIL LEVEL INPUT
3 A2 A3
OIL LEVEL
SWITCH RED +5 VDC AUXILIARY OUTPUT / OIL LEVEL
B8 B7

CRS COMPRESSOR ROTATION INPUT


BLU BLU
3 A3 A4
ROTATION
INVERTER
SWITCH PROOF
INVERTER RUN
3 A4 A5 C5 COMPRESSOR OUTPUT
INVERTER PROOF INPUT
RUN PROOF C4

OFS
BRN BLU DIGITAL OIL FLOW INPUT C6 PART WINDING OUTPUT
3
A5 A2
OIL FLOW
SWITCH
REMOTE ALARM RESET INPUT C7 LOADER #1 OUTPUT
3
A6 A7
C5
REMOTE ALARM
RESET OUTPUT
DIGITAL INPUT COMMON / GROUND C8 LOADER #2 OUTPUT
3 A7 B6
NOTE: C6
IT IS VERY IMPORTANT FOR THE
CORRECT OPERATION OF THE
ESC 201 THAT THIS GROUND C9 OIL SOLENOID OUTPUT
CONNECTION IS PROPERLY WIRED.
MOTOR OVERLOAD C7
CMT
T1 T2 INPUT
4 B1 B1 C10 ALARM OUTPUT
MOTOR
CDT DISCHARGE
BRN THERMISTORS
BLU TEMPERATURE
4 B2 B2 C11
INPUT ECONOMIZER OUTPUT
DISCHARGE
GAS THERMISTOR C7
JKT
4 JET KOOL TEMPERATURE B3
INPUT
JET KOOL
TEMPERATURE SENSOR
0 - 500 B4
DISCHARGE PRESSURE INPUT
RACK DISCHARGE
TRANSDUCER
0 - 100 B5
RACK SUCTION SUCTION PRESSURE INPUT
TRANSDUCER
OFT
4 OIL FLOW B6
TRANSDUCER INPUT
OIL FLOW
TRANSDUCER
A8
+15 VDC AUXILIARY OUTPUT
4
B7 B6
ANALOG INPUT COMMON / GROUND
ESC 201
PHASE CONNECTIONS
NOTE:
IT IS VERY IMPORTANT FOR THE PHASE PHASE PHASE
CORRECT OPERATION OF THE
ESC 201 THAT THIS GROUND A B C
CONNECTION IS PROPERLY WIRED.

ESC 201
PHASE CONNECTIONS
LINE VOLTAGE WIRED
FROM THE LOAD SIDE
OF THE COMPRESSOR
CONTACTOR ESC-200-201.WMF
REV 'A'

(Cx) ESC ter minal number Page 52 of 67 ESC201C-4-23-02


Preliminary Data Subject to change 4/22/02
Appendix H
ESC 201 Low Voltage Transformer Wiring Diagram

SEE NOTE BELOW


20 VAC CENTER TAP
ESC 210 TRANSFORMER
SHIELDED CABLE

ESC 201 POWER CONNECTION

AC GND AC
20 VAC CENTER TAP
LINE VOLTAGE
AC GND AC ESC 201 TRANSFORMER CONNECTION
208-230/60/1

(VIEW FROM TERMINAL END)

JUMPER

JUMPER AC AC
TYPCAL CONNECTION 208-230/60/1
FOR ALL THE ESC 201'S ESC 201 CONTROL POWER
208-230/60/1 POWER
CONTROL POWER

SEE NOTE BELOW 20 VAC CENTER TAP


ESC 210 TRANSFORMER

SHIELDED CABLE

ESC 201 POWER CONNECTION

AC GND AC
LINE VOLTAGE
20 VAC CENTER TAP CONNECTION
ESC 201 TRANSFORMER
AC GND AC 208-230/60/1

(VIEW FROM TERMINAL END)

AC AC
TYPCAL CONNECTION 115/60/1
FOR ALL THE ESC 201'S ESC 201 CONTROL POWER
115/60/1 POWER
CONTROL POWER

NOTE:

DO NOT CONNECT ANY WIRES TO THE GROUND TERMINAL ON THE TRANSFORMER.


THE ESC 201 DOES NOT OPERATE ON A CENTER TAP TRANSFORMER.

C:\ESC201\ESC-201-TRAN

(Cx) ESC ter minal number Page 53 of 67 ESC201C-4-23-02


Preliminary Data Subject to change 4/22/02
Appendix I
ESC 201 Trouble Shooting Guide

Note: After each change has been made in the configuration mode that change must be
saved in that section for the change to be initiated.

ESC input voltage w ill read 5VDC from the function ter minals ( A1-A6) to ground (A7) and
from Ter minals (B1-B6) to Ground (B7).

ESC output ter minals ( C5 – C11) are supplied voltage from Ter minal C12. This voltage can
be read from terminals (C5 – C11) to L2 w hen the output function is closed.

Ter minal (C1- C4) are high voltage input ter minals nor mally using control voltage as a
source.

Problems Possible Solutions

ESC w ill not pow er up. Check for 24 VAC control pow er to terminals mar ked
A/C.
Check for proper electrical connections to transformer
or faulty transformer.

Check F2 fuse on the ESC board upper left corner.

Check to insure total number of ESC 201 controllers


have not exceeded the transformer pow er limitations.

(C1) input is not present Check for voltage and electrical connections betw een
the compressor control sw itch, pressure controls,
overload contacts and other control devices to input
point C1.

No output pow er at (C4 – C11) Check for proper input voltage at ter minals (C1 & C11).

Check F1 fuse at low er right corner of board.

ESC operates inter mittently Make sure ground has a good non-painted connection.

Make sure all fuses are tight in the fuse holder.

F1 fuse blow s when the ESC Turn off Compressor Breaker.


is energized
Check the input & output points for short circuits in the
w iring.
Step #1 Disconnect (C1) control input and ( C5 & C6)
control output from the ESC and connect the w ires
together, isolating the ESC control. Activate the
compressor control circuit. If the compressor
contactor closes, proceed to step # 2.
(Cx) ESC ter minal number Page 54 of 67 ESC201C-4-23-02
Preliminary Data Subject to change 4/22/02
Problems Possible Solutions

Step #2 De-activate the compressor control circuit


and reconnect (C1, C5 & C6) points on the ESC.
Disconnect output points (C7 to C11). Activate the
compressor control circuit. If the compressor
contactor closes, connect point (C7) and test this
point. Test Points ( C8 – C11) w ith the same
procedure. If any of these tests produce a blow n fuse,
then check the corresponding circuit for the short.

Phase loss alarm turns on after The phase voltage leads from the ESC 201 are
a motor breaker closure, w hile connected to the line side of the compressor contactor.
the compressor control circuit Connect leads A,B,C to the load side of the compressor
is inactive: contactor. (The preferred locations are the
compressor terminals T1,T2,T3)

ESC fails after an inverter fault: Compressor input signal (C1) remains active during
inverter reset attempts.
Check to insure inverter relay is not defective.
Check control circuit w iring diagram to insure the
inverter isolation scheme has been included.
Refer to the inverter fault scheme diagram in
section 1.6 (Contact factory for help w ith this scheme if
required)

Phase rotation failure: Correct the compressor rotation.

Rotation failure, but compressor Phase sequence of A,B,C on the ESC 201 must be
operates in the correct direction:
changed to match the proper electrical
rotation sequence.
Once the proper sequence has been deter mined and
set, change any tw o leads of the phase leads on the
ESC 201control to align the system electrically.

Open type compressors indicate Configure Esc 201 in the setup program for the motor
Motor overload failure: overload as “Disabled”

All compressors in the same Check the compressor start time delays to insure they
suction group start at the same have been configured properly.
Time:

Compressor fails on phase: Check voltage at all three phases to determine If


Voltage exists.

Discharge temperature failure: Check discharge temperature for out of range


condition. High compressor super heat or insuffic ient oil
cooling w ill cause this problem.

ESC 201 alar ms in critical Discharge temperature has been above 200°F for more
discharge temperature and than 20 minutes. Check oil cooling and other cooling
shuts dow n the Compressor: criteria.

(Cx) ESC ter minal number Page 55 of 67 ESC201C-4-23-02


Preliminary Data Subject to change 4/22/02
Problems Possible Solutions

Motor overload failure: Check motor temperature to deter mine if it is out of


range.
Read DC voltage betw een terminals (B1 & B7). The
voltage should be stable betw een 0.3 & 0.6 VDC. The
thermistor trip point is 2.3 VDC.

Make sure all Ther mistor connections at the


compressor are tight on the spade connectors. Check
the ESC setup program for proper configurations.

Dirty oil filter failure: If dirty filter alarms on initial start, depress reset button
to initialize the sw itch. This procedure is required one
time after an oil change or possible initial start. Sw itch
opens w ith oil pressure differential across the filter of 25
PSI. Check w iring of switch for N/C operation w hen
clean.

Oil Flow Failure: Check for low oil conditions: such as dirty oil filter, liquid
refrigerant present in the oil system, blocked oil system.
Check to make sure oil line blank off plate has been
removed from compressor oil fitting.
Check to make sure the oil flow sw itch has been w ired
properly to the Esc 201.
Check to make sure the proper differential pressure
exists betw een discharge and suction to flow the proper
amount of oil to the compressor.

Oil level failure: Check oil level in separator for proper level. Check to
see if the optical sensor is receiving a 5VDC signal.
Check for loose w ires from sensor to the ESC.

Com pressor fails on run proof: Check to insure run proofs are connected to the proper
auxiliary contacts.
Check F1 fuse for continuity.
Make sure run proofs signal on direct on line is
connected to C4 w ith 115 –120 VAC.
Make sure the direct–on-line and the inverter run proof
are being energized together.

Econom izer Solenoid won’t Economizer superheat below minimum set point.
energize: ESC 201 has shut dow n the ECO solenoid to protect
the compressor against potential bearing damage.
“ LOW ECO TEMP.” is displayed by ESC 201.
ESC alar m:

“Low Discharge Temperature” Suction superheat extremely low causing a low


discharge temperature condition. Adjust evaporator
expansion valves.

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Preliminary Data Subject to change 4/22/02
Problems Possible Solutions

Wiring Fault Alarm Check to m ake sure the three-phase w ires are
connected from the load side of the contactor to the
ESC 201 three-phase connections. This fault w ill
occur if these wires are connected to the line side of
the contactor.

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Preliminary Data Subject to change 4/22/02
TM

JET KOOL
Jet Kool Installation & Operation Manual

18.0 Jet Kool System


18.1 Description

Jet Kool is the latest development of a safe and efficient means to perform oil cooling on
Copeland screw compressors utilizing system refrigerant. Liquid refrigerant is supplied by the
condenser liquid return line through a primary receiver to the inlet side of a plate heat
exchanger, designed for oil cooler duty. The return line from the plate heat exchanger is
connected to the jet pipe nozzle connection, located in the discharge line of the refrigeration
system. The purpose of the jet pipe is to create a low er pressure in the Jet Pipe than in the
discharge line entering the Jet Pipe, providing a positive flow of refrigerant vapor back to the
condenser. The jet pipe provides an adequate pressure differential to operate the oil system
and overcome the nor mal refrigerant pressure drops found in the discharge line, refrigerant
condenser and liquid return line. Jet Kool does not affect compressor performance or
capacity, since the refrigerant used for oil cooling purposes does not influence the suction side
of the system or the mass flow pumped by the compressor.
Refrigerant oil from the oil separator passes through the plate heat exchanger to the
compressor oil circuit. Oil heat is transferred in the plate heat exchanger to the system
refrigerant and sent to the condenser. The oil, refrigerant and compressor loads make up the
total heat of rejection in the screw compressor.
Compressor discharge temperatures are monitored by the ESC 201 at each compressor
discharge or on the common header for some parallel systems. Based on system demand the
ESC 201 provides a 0–24 V DC signal to a refrigerant control device, located in the liquid
refrigerant line, feeding the plate heat exchanger. This refrigerant control device provides the
proper amount of liquid refrigerant to the plate heat exchanger inlet, maintaining the precise oil
temperature to furnish a safe compressor discharge temperature.
The proper control of compressor discharge temperature is essential to a safe operation of the
compressor. Discharge temperature must be maintained at 50°F above condensing
temperature to prevent liquid form condensing in the discharge line or oil separator. If gas is
condensed into a liquid prematurely in the discharge system, liquid w ill be returned in the
compressor oil system, causing compressor-bearing damage. The Jet Kool oil cooling system
should be set to control the discharge temperature at 180°F.

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Preliminary Data Subject to change 4/22/02
19.0 Jet Kool Components
19.1 Listed below are the Jet Kool kit components provided with Jet Kool.

A. Jet Pipe
B. Plate Heat Exchanger
C. Liquid Flow Control Valve
D. 1 ¾”-12 x 1 3/8” O.D.S. Fitting (4)
E. 1 3/8” Rotalock Valve
F. Primary Receiver and Bracket
G. Liquid Check Valve

19.2 Listed below are additional components required, not supplied with Jet Kool.

I. Liquid Sight Glass (Additional sight glass optional in pipe P4)


J. Isolation Ball Valves (3 required)
K. Access Fittings (5)
L. Discharge Ball Valves

20.0 Jet Kool Piping Specifications

20.1 Minimum Condenser Height

The below listed pipe specifications are in accordance with Jet Kool Flow Diagram (section
21.0) of this manual. The vertical height distance from the bottom of the condenser liquid
outlet to the plate heat exchanger refrigerant inlet must be a m inimum of 6 FT.

20.2 Primary Jet Cool Condenser Line (P1)


All pipes, valves and fittings exiting the jet pipe must remain the same size as the jet pipe
outlet diameter or a combination of multiple pipes, valves, and fittings totaling the equivalent
cross sectional area of the jet pipe outlet.

20.3 Split Condenser Line (P2)


If split condenser is required, the split valve outlet cross sectional areas must total the cross
sectional area of the jet pipe outlet. The full condenser side discharge pipe exiting the split
valve must not be s maller than the total cross sectional area of the jet pipe outlet.
Example: If the Jet Pipe outlet is 2 1/8” in diameter, both discharge lines after the split valve
must be a minimum of 2 1/8” in diameter.

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Preliminary Data Subject to change 4/22/02
20.4 Oil Cooler Liquid Line (P3)
Liquid line from the primary receiver feeding the plate heat exchanger refrigerant inlet must
have a shut-off valve ( Rotalock or Ball), sight glass, low-pressure drop liquid check valve
(supplied), access fitting and refrigerant flow control in this sequence. These components
must be sized in accordance w ith table 1.1.

Table 1.1

Maximum Oil Cooling Capacity (KBTU’S) Minimum Line/Connection


R-22 R404A/507 Size
0-250 1 1/8” OD
0-160 1 1/8” OD
250-400 1 3/8” OD
160-250 1 3/8” OD

20.5 Oil Cooler Vapor Return Line (P4)


The refrigerant outlet from the plate heat exchanger to the jet pipe nozzle inlet must be as
short as possible w ith the least amount of elbows keeping this pressure drop to a minimum.
This line must have an isolation ball valve, (optional sight glass), and access fitting in this
sequence w ith a 1 3/8” line size, corresponding to the Jet Pipe Nozzle Rotalock size of 1 3/8
OD.

20.6 Hot Oil Feed Line (P5)


The oil inlet to the plate heat exchanger must be sized according to table 1.2 listed below w ith
an access fitting.

Table 1.2
Number of compressors Oil line size OD.
1-2 1 1/8”
3-4 1 3/8”
5-6 1 5/8”

20.7 Cool Oil compressor Feed Line (P6)


The oil outlet from the plate heat exchanger must also be sized in accordance to table 1.2 w ith
an access fitting and isolation ball valve in this sequence.

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Preliminary Data Subject to change 4/22/02
21.0 Jet Kool Component Specifications
21.1 Jet Pipe Description
Jet pipes are available in one series, “HR 66”. If the capacity range of the system exceeds the
maximum pipe capacity, then more than one pipe may be required. The pipe is constructed of
aluminum w ith flanged braze connectors. The series “HR 66” has a 2 1/8” inlet & outlet and a
1 ¾ -12 (1 3/8”) rotalock connector at the nozzle. Access fittings are provided at the outlet of
the jet pipe for reading this pressure. Access fittings are also required at the pipe inlet &
nozzle inlet during installation for the same purpose. Diameter of the inlet and outlet discharge
line at the Jet pipe must remain the same size as the Jet pipe inlet and outlet size.
Reference (Jet Kool Flow Diagram, section 23.0)
The jet pipe is placed in the discharge line in position P1. The Jet pipe must be installed after
the last heat reclaim valve or pressure differential valve and before the split condenser valve.
When piping the jet pipe into the system, a few considerations should be adhered to for
positive operation of the JET Kool System.
1. Do not reduce the pipe size from the outlet of
the jet pipe to the inlet of the condenser,
Refrigerant Outlet
including the split condenser valve sizing.
2. If a ball valve is required betw een the jet pipe
and the condenser, insure that this valve is
full ported. Any reduction in line or port sizes
from the outlet of the jet pipe to the inlet of the
condenser w ill affect the performance of Jet
Kool.
Nozzle Inlet
3. Access fittings must be installed on the Jet
Pipe refrigerant inlet and the nozzle inlet.
These fittings are required to check the
performance of the Jet Pipe.
Refrigerant Inlet
4. Placement of the Jet Pipe can be either in the
horizontal or vertical positions. The pipe nozzle
should be pointing tow ard the oil cooler refrigerant
outlet to eliminate additional elbow s. Refrigerant Out

21.2 Oil Cooler Plate Heat Exchanger Description


The plate heat exchanger is a brazed plate device w ith alternating
refrigerant and oil passages separated by heat exchanger plates.
As the refrigerant and oil past each other, the heat from the oil is
transferred to the refrigerant. Both tw o pass and single pass
counter flow type plate heat exchangers are utilized, depending
upon the required load size.
Liquid Refrigerant Inlet

Four mounting studs are provided for mounting the heat exchanger
on the rack. Fluid connections for the refrigerant and oil are 1 ¾”-12
male Rotalock connectors. The tw o pass oil coolers have the Hot Oil In
refrigerant Oil Out
connections vertically opposed w hile the oil connections are on
opposite sides. The refrigerant inlet is on the low er left connector,
with the refrigerant outlet on the upper left connector.

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Preliminary Data Subject to change 4/22/02
The oil inlet & outlet connections
are interchangeable. Single pass oil cooler connection fittings are located on the same side of
the heat exchanger. These must be piped in a counter flow configuration w ith the refrigerant
inlet on the low er left and the oil outlet on the low er right (Figure not show n).
Reference (Jet Kool Flow Diagram, section 23.0)

The plate heat exchanger is piped betw een refrigerant side positions P3 and P4 and the oil side
positions P5 & P6. The plate is to be mounted on low est possible position of the rack frame in
an area directly below the jet pipe (if this is not possible please consult the factory). This
position w ill allow for a short refrigerant return line from the plate outlet to the jet pipe nozzle
inlet ( P4 piping configuration).

21.3 Liquid Flow Control Operation


Description
A flow control valve (JKV-100) is used to control the amount of refrigerant flow to the plate
heat exchanger. The discharge temperature requirement deter mines the volume of refrigerant
required to performing oil cooling. A 0-22 VDC signal is sent to the flow control valve from the
ESC 201. The ESC 201 also monitors the discharge temperature by using either the PT 1000
sensor mounted in the compressor discharge or the rack sensor mounted on the discharge
header.

ESC 201 Configuration


Proper configuration of the ESC 201 is essential to the correct Jet Kool operation. When the
discharge temperature is sensed at each compressor discharge port, the “Temperature
Probe” function in the ESC 201 must be configured as “PT1000” and the “Jet Kool
Temperature” function must be assigned as “Compressors”. When the “Tem perature
Probe” function is configured as “PTC”, a single high temperature probe must be installed on
the discharge header and the “Jet Kool Temperature” function must be assigned as “Rack
Sensor”. The valve position and refrigerant flow are contingent upon this voltage signal. The
constant control of oil temperature maintains the necessary discharge temperature setting.
Reference (Jet Kool Flow Diagram, section 23.0)
The flow control must be placed as close as possible to the plate heat exchanger refrigerant
inlet and after check valve (H) in pipe P3. The valve should be properly supported and
mounted in a location w here physical contact and condensation w ill not affect the life or
performance of the valve. The flow valve should be positioned in the same plane as, or above
the heat exchanger refrigerant inlet to prevent a negative effect on any liquid head advantage.

21.4 JKV 100 Ana-loid Valve


The JKV 100 Ana-loid valve manufactured by Parker is
used to meter refrigerant to the Jet Kool plate heat
exchanger. This valve is operated from the ESC 201
control w hich receives a 0 –22 VDC signal. The valve
modulates from full open to 90% closed controlling the
amount of refrigerant flow to the heat exchanger. JKV
100 has a ductile iron valve body w ith 1 3/8” copper
braze fittings.

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Preliminary Data Subject to change 4/22/02
21.5 JKV 100 Ana-loid Coil
Positioning of the Ana-loid 24V coil on the valve stem is extremely important. The coil must be
placed on the stem w ith the coil base flat against the valve housing. A screw is provided to
secure the coil to the valve. This screw must be in place or the valve w ill not properly operate.
If the screw is not in place the coil w ill travel up on the plunger, preventing the valve from
opening and closing.

21.6 Setting Manual Oil Cooling

In the event of electronic component failure of either the JKV 100 coil or the ESC 201, the JKV
100 can be manually operated by the manual opener located on the dow nstream side of the
valve in the adapter assembly. Remove the seal cap covering the manual opener screw on
the adapter assembly.
The Ana-loid valve can be adjusted w ith the manual opener screw from closed to fully open
with one full turn counter-clockw is e. Adjustments betw een open and closed can control the
flow through the valve to achieve the proper discharge temperature w hen operating in the
manual mode. A discharge temperature of 150°F – 155°F is desired w hile operating in the
manual mode.

To set this temperature, turn the manual opener 1/3 of a turn counter-clockw ise and allow the
temperature to stabilize. If the temperature has not been achieved a second and third
adjustment may be required.

Specifications: ANA-LOIDCOIL24V

Ana-loid Coil Voltage: 24VDC


Design Pressure: 450 PSIG MANUALOPENER ADAPTERASSEMBLY
Maximum Pow er: 7 Watts CARTRIDGE
ASSEMBLY
FLOW
OUTLET INLET

21.7 Oil Cooler Fittings


Description
Four 1 ¾” – 12 X 1 3/8” ODS rotalock adapter fittings are supplied to connect refrigerant and
oil lines to the plate oil cooler. An additional fitting may be supplied to connect the primary
liquid refrigerant outlet to pipe P3, if the customer prefers a ball valve in place of a rotalock
valve.

21.8 Primary Receiver Shut off Valve


Description (Jet Kool Flow Diagram, section 22.0)
A steel 1 3/8” rotalock valve is supplied for mounting on the bottom of the primary receiver.
This valve is used to shut off refrigerant and isolate the liquid flow control valve located in pipe
P3. A ball valve can also be utilized for this application as a customer preference.

21.9 Primary Receiver


Description (Jet Kool Flow Diagram, section 23.0)
(Cx) ESC ter minal number Page 63 of 67 ESC201C-4-23-02
Preliminary Data Subject to change 4/22/02
A steel receiver is provided as a refrigerant reservoir to be installed in the system condensate
drain line. This receiver provides a solid column of liquid to the plate oil cooler to insure
positive heat transfer. Receiver is a flow through vessel holding approximately 3 gallons of
liquid. A ½” NPT port is provided in the top dome for installation of a pressure relief valve.
Valve type and relief setting is dependent on system refrigerant. Relief valve is not supplied in
the jet Kool Kit.

21.10 Liquid Check Valve

Description (Jet Kool Flow Diagram, section 23.0)


Check valve is a Muller model # B34237 w ith less than ½ lb. pressure drop. This valve insures
the refrigerant flow direction cannot reverse during pressure changes or surges. The valve is a
full-ported 1 3/8” w ith 1 3/8” ODS. inlet and outlet connections. DO NOT SUBSTITUTE
COPPER SPUN BALL CHECK VALVES. These valves normally have pressure drops that
exceed the system specifications.

21.11 Liquid Sight Glass


Description (Jet Kool Flow Diagram, section 23.0)
A 1 3/8” ODS liquid sight glass is required in line P3 to make sure a solid column of liquid is
present at all times. An optional sight glass of the same line size as P4 may be placed in this
line.

21.12 Isolation Ball Valves


Description (Jet Kool Flow Diagram, section 23.0)
Ball valves are required in lines P3, P4 and P6 to isolate the plate oil cooler, if replacement is
required. These ball valves w ill also per mit servicing of the Ana-loid valve. It is strongly
recommended that ball valves be placed in line P1 before and after the Jet Pipe. Along w ith
the ball valve in line P4, the valves in line P1 w ill accommodate the removal of the Jet Pipe for
changing the nozzle.

21.13 Access Fittings


Description (Jet Kool Flow Diagram, section 23.0)
Five ¼” access fittings w ith cores are required in lines P3 (2), P4, P5, and P6 to qualify and
troubleshoot the system.

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Preliminary Data Subject to change 4/22/02
22.0 Troubleshooting the Jet Kool system

Problem Possible Solution

1. System w ill not operate 1. If hot gas or cool gas defrost system has a
during hot gas defrost: master liquid line valve (pressure dif ferential
valve) it is highly possible the condenser hot
gas is being circumvented and not supplying
receiver.

2. System w ill not control 2. Refrigerant charge is low and not feeding liquid
the discharge system to the primary receiver, and not supplying a
temperature: solid column of liquid to the oil cooler. The
liquid system cannot hav e any gas bubbles.

Check the JKV 100 liquid valve to insure it is


opening properly. Suggest opening the valve
manually if there is any doubt about the valve
operation.

Check to make sure the liquid line from the


condenser feeding the primary receiver falls
from the condenser to the receiver. The liquid
return line must fall w ithout any risers to the
receiver or to the oil cooler from the outlet of
the primary receiver.

3. The System has operated for a long 3. Check for low refrigerant charge.
period of time, then suddenly There must be a solid column of liquid
stopped w orking: betw een the primary receiver & the Analoid
valve.

Check system set points to make sure they


have not been low ered. Jet Kool system has
been calculated on a specific set of system
setpoints. If the mass flow has been low ered
this w ill adversely affect the oil cooling
required and the Jet Pipe performance.

If the solid column is inter mittent, check for


changes in hot-gas defrost schedules in the
rack controller. (if applicable).

Consult factory for possible solutions if the


setpoints have been altered.

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Preliminary Data Subject to change 4/22/02
Troubleshooting the Jet Kool system (continued)

Problem Possible Solution

4. JKV 100 valve is not receiving 4. Check master ESC 201 to insure a signal is
an electrical signal: being sent from the Jet Kool ter minals.

Make sure the ESC 201 master has been


configured for “Jet Kool” in the setup
program.

Check the ESC 201 for the proper discharge


temperature probe setup. If the temp sensors
from each compressor are used to calculate
the discharge temperature, then the “Jet Kool
Temperature Source” should be
“Com pressors”.
If a single sensor is used from the rack
discharge header, then the “Jet Kool
Temperature Source” should be “Rack”.

Also check the “Jet Kool Target Tem perature”


for the proper setting.

5. Jet Kool w ill not w ork in split 5. Check to see if discharge lines are the same
condenser mode: size out of the split valve as they are out of the
Jet Pipe.
These lines must not be reduced out of the split
valve. (The Jet Pipe must have a minimum of
2-1/8” O.D. from the Jet Pipe outlet to the
condenser inlet). Both discharge lines exiting
the split valve must be a minimum of 2 1/8”
O.D. to the condenser inlets.

Check pressure drop across the condenser


while in and out of split. Extremely high
pressure drops when in split w ill adversely
affect the Jet Kool performance.

Check the condenser split setup to make sure


it is not sw itching into split above the
manufacturer’s recommended setting.

Make sure the condenser fans are shutting


dow n on the proper side w hen in split.

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Preliminary Data Subject to change 4/22/02
23.0 Jet Kool Flow Diagram

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Preliminary Data Subject to change 4/22/02

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